Complete EDM

Finding The Right Carbide Cutter And Carbide Tooling For Die-Mould Applications

The die/mould industry depends heavily on using the best available carbide cutter and other carbide tooling. Whether you are building a plastic injection mould, or a precision metal stamping die, the carbide end mill plays a critical role.

With the advent of high speed and hard machining, the tooling has become even more important. Some of the tougher tool steels, such as D2, M2, H13, S7 and 420SS demand a high quality cutter in order to perform properly.

Various companies have invested heavily in research and development to meet this demand. There are new substrates that perform much better than those of the past. The newer coatings can dramatically improve the surface finish, metal removal rate and cutter life.

Some manufacturers have as many as 15-20 carbide substrates they use and coat with TiN , TiCN, AITiN, TiAIN, ZrCN, TiC, Al2O3. They use a process called PVD, (physical deposition process), or another process, CVD (chemical deposition process. One chemical process has up to 70 extremely thin layers on the substrate!

Various companies

Sandvik inserts are a good example of this push toward greater productivity. The new kordell grade GC1640 is the next stage in optimized Plura milling performance. They offer a unique concept with VFD, or variable flute design that aids in roughing and semi-finishing applications. Their line of CoroMil includes the 318 end mill, which is the first product in their line with the new exchangeable head milling system. The CoroMil 345 is a face mill system that is commonly used to remove a lot of stock, very quickly and with a minimum of heat build up.

OSG has developed their line of solid carbide endmills that feature a new substrate and coating. The EXOCARB WXS line improves tool life dramatically, especially when hard milling tough hardened tool steels, such as D2. OSG also has the EXOCARB HP ball end mill that features a TiAIN coating that enhances the performance and prolongs tool life.

Other companies, such as ISCAR's 3P Sumo Tec coating, Melin with their 2 flute nACo solid carbide micro endmill line, and American Carbide's line with PCD inserts , make this a very competitive market indeed.

Carbide tooling and holders

One of the leading suppliers for tool holders is Schunk. They have many types of precision tool holders, such as Celsio shrink fit, hydraulic Tendo expansion tool holders, and the Sino universal tool holder.

Big Kaiser offers the New Baby, HMC chucks, Mega chucks, and HSK tooling. These holders are rugged and designed for real world use and abuse.

Nearly any of the leading suppliers will be all to happy to introduce you to their line of products and allow you to test them in your machines. This is really the best way to determine which is right for your particular application. Everything looks great in a catalog or tool show, but using it in a real life situation is the only real test.