Machining Operations through Utilising Ceramic Inserts
13 April 2023
Manufacturers carry out machining operations to ensure that the products needed by various industries can be produced without any quality issues. Machining operations can help achieve their needs as they can cut some parts of the workpieces.
Of course, machining operations can only be carried out successfully with the help of the right tools and machines. Some tools and machines that can be used to conduct machining operations include drill presses, screw machines, milling machines, gear shapers, and lathes. One common thing about these machines is they rely on mechanical internal parts to make everything work. But as they move and operate, they tend to wear and deteriorate quickly, which can compromise product quality as time passes.
Hence, durable inserts should be utilised by manufacturers in conducting machining operations. Inserts or indexable inserts are utilised as the cutting edges for machining tools. Many materials can be used for inserts. One of these materials is ceramic.
Processing Ceramic as an Insert
As mentioned earlier, inserts can be produced out of various materials. Some materials that can be used to generate inserts are tungsten carbide, silicon nitride, and high-speed steel. However, one material that stands out among the rest is ceramic.
Ceramics are hard, heat-resistant, and corrosion-resistant that are comprised of inorganic, non-metallic materials like clay, silica, and feldspar. They are then integrated with earthen elements, powders, and water and shaped the material into various forms. Once ceramics are converted into inserts, they can boast benefits that other types of inserts may lack.
Key Benefits of Ceramic Inserts
One of the benefits of ceramic inserts is they are heat resistant. The operations of machines and tools needed to manufacture parts can generate a lot of heat. After all, the tools will be in direct contact with the workpieces all the time. Ceramic inserts, fortunately, can resist heat and high temperatures, allowing them to process a wide range of materials before they wear out. Even at higher cutting speeds, ceramic inserts can swiftly generate products in a short time without getting damaged or deteriorating.
Another benefit of ceramic inserts is they can last for multiple operations. Ceramics on their own can be more brittle than other materials. However, they can be enhanced by adding more components to their general composition so they can last longer. Silicon carbide, for instance, can be added so that ceramic inserts can withstand excessive vibration from machines. It also allows the inserts to withstand shocks that may be present during machining operations.
These benefits then make ceramic inserts versatile as they can cut through hard metals without introducing any cracks on the workpieces.
Machining with Ceramic Inserts
Industries can take advantage of ceramic inserts for their machining applications. Some machining processes that can benefit from ceramic inserts are turning and milling.
Machining with ceramic inserts, nevertheless, should still be carried out with utmost care. Edge preparation, for instance, should be matched based on a specific application. This factor is often comprised of three parameters: land angle, land width, and honing size. Large values of each parameter mean that the cutting edge may become stronger. Stability should also be maintained to ensure that ceramic inserts can work optimally.
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