Invest in Ceramic Inserts from Amon Engineering
07 November 2022
Machining is the process of cutting workpieces into the desired shape and size of a specific product. During this process, small chips and pieces of the workpieces are removed, making sure that only the needed parts will remain.
Many industries today rely on machining as it can provide tons of benefits to their operations. For one, machining can produce many parts and products in one go. It is also accurate and precise, especially when high-quality tools are used in carrying out the machining operations. Efficiency is even enhanced with machining since less time, effort, and waste are expected. Machining is also reliable and profitable.
But these benefits can be enhanced further once special tools and mechanisms are used for machining. Ceramic inserts, for instance, can be used to achieve better results.
A Quick Introduction to Inserts
Inserts, in general, are removable cutting tips that can be used in material removal processes. They are not brazed, welded, or attached to the body of machining tools, allowing machining companies to exchange or swap them whenever needed. They can even be flipped or rotated without causing any disturbance to the tool geometry.
Many materials can be used in creating inserts. One of these materials is ceramic. Ceramic inserts are often comparable to carbide inserts, as the latter has been very useful in carrying out turning applications. But ceramic is now known to be a great alternative to carbide since inserts made from this material provide tons of benefits to machining companies.
Key Benefits of Ceramic Inserts
Ceramic inserts can be made from either aluminium oxide or silicon nitride. These elements allow these inserts to have a hardness of about 2,100 to 2,500 HV. These values make ceramic inserts 40% harder than their carbide counterparts, allowing them to cut through a wide range of materials without any issues.
Aside from their hardness, ceramic inserts likewise boast chemical stability in both high and low temperatures. Their low thermal conductivity then allows the transfer of heat to the chip instead of the cutting tool. Ceramic inserts can also boast various colours and compositions that allow them to process different materials for varying applications. Some materials that ceramic inserts can process are hardened steel, nickel-based alloys, and cast iron.
Machining with Ceramic Inserts
The hardness of ceramic inserts allows them to be useful in processing different materials. But this specific benefit can also be a disadvantage since it makes these inserts more brittle. Hence, they can easily break if they are not handled optimally.
One factor that should be considered to keep ceramic inserts operational is edge preparation. It refers to the micro-geometry of the cutting edge. When cutting with ceramic inserts, the edge preparation should be considered based on a specific application. Hence, ceramic inserts should maximise varying edge preparations for each geometry to make them work optimally.
Stability is another factor that should be considered when machining with ceramic inserts. Increasing the stability of the ceramic inserts may be done through firm tool clamping, optimal workpiece support, and short overhang.
To acquire quality ceramic inserts, you can contact us at Amon Engineering. Our factory workshop is well-equipped to service the demanding needs of the engineering market and can handle all types of tooling from simple washers to the most complicated components.
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