Cutting Tool Applications Aid in Machining Tungsten Heavy Alloys

Tungsten Products supplies a number of industries with a difficult-to-machine material--tungsten heavy alloys. The heavy alloy products produced by the company provide a special combination of density, mechanical strength, machinability, corrosion resistance and economy. Unfortunately, the positive aspects of this material can also provide some unique challenges during machining.

Randy Shank, Stellram service engineer, and Nick Gaten, global milling manager, recently improved Tungsten Products' machining operation with some new grades and geometries. A new high positive, -441 milling geometry, along with a shell mill using octagonal inserts, was tested on a rotary-wing aerospace part for reducing vibration and counterbalancing. This new geometry, designed for aluminum and titanium operations, provides freer cutting and reduces the "suction effect" normally associated with higher helical geometries.

Machining tungsten heavy alloy is similar to machining gray cast iron, because the material is highly abrasive, with the chips being discontinuous. Carbide tools should be used for milling, turning and drilling. Cutting speeds and feeds arc generally less than when machining cast iron, and the use of coolant is suggested for roughing but is not required when finishing. Unlike machining cast irons, where chipbreakers arc rarely needed, tungsten requires positive edges to prevent edge build-up.

Many of Tungsten Products' customers are in the medical and aerospace field and require extremely tight tolerances. Applications for these materials range from therapeutic medical radiation shielding, aerospace weights and counterbalances, helicopter rotor applications, and down hole logging, to recreational applications such as golfing, racing and firearms.

A new precision ground geometry from Stellram, the 3F, offered a perfect solution for some of the precision machining required on these components. The 3F, like the 441 milling geometry, is a high positive geometry with sharp edges and small nose radii. It is intended for high temperature alloys and aluminum.

This geometry, along with a new TiAIN grade, SP3 064, and a 0.003 inch nose radius, increased tool life by nine to 12 times. Another turning application with the same geometry and grade allowed a 20 percent increase in speed and a 50 percent increase in feed with 40 percent longer tool life.

Tungsten Alloy Manufacturer & Supplier: Chinatungsten Online - http://www.tungsten-alloy.com
Tel.: 86 592 5129696; Fax: 86 592 5129797
Email: sales@chinatungsten.com
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