Cutting of Difficult-to-Process Metal Materials
Cutting of difficult-to-process metal materials poses a challenge for engineers. The difficulty generally results from the need to process material with an extremely hard surface, one that is resistant to cutting or has drilling characteristics that are drastically different from those of softer materials. Such material often presents high levels of wear and tear on cutting tools, rendering them ineffective with time.
One way to overcome the challenges posed by working with difficult-to-process materials is to use specialized cutting tools. Polycrystalline diamond (PCD) materials and ceramic cutting tools, for example, have a high resistance to wear, and offer cutting capabilities that surpass those of traditional cutting tools. For example, drills made of PCD can drill through tough materials in less time than traditional drill bits because of their superior cutting force. They can also be used for fine drilling operations, such as micro-drilling of surfaces.
Another consideration when cutting difficult-to-process metal materials is the type of cutting tool used. The choice of tools primarily depends on the materials hardness. For hard materials, such as steels, carbide cutting tools should be considered. These tools are made from a combination of tungsten carbide and cobalt, and offer superior cutting abilities due to their high-alloyed composition. For softer materials, such as aluminum or brass, high-speed steel cutting tools should be used. High-speed steel, commonly abbreviated as HSS, is one of the most commonly used tool materials and is known for its excellent cutting properties.
When cutting difficult-to-process metal materials, it is also important to monitor the speed, feed rates, and cutting forces used. If the process is not monitored, it can cause rapid tool wear and lead to poor cut quality. Several strategies can be used in order to minimize tool wear, such as varying the cutting speed, alternating between chip and non-chip forms of machining, or utilizing specific drill and cutting edge geometrics. Additionally, it is beneficial to use a coolant when machining difficult materials, as this helps reduce tool wear, especially at high cutting speeds.
An additional consideration when attempting to cut difficult-to-process materials is the selection of abrasives. Abrasives are materials that are used to remove material from a surface. Common abrasive materials include sandpaper, emery cloth, diamond powder, and silicon carbide. abrasives can be used for light grinding operations and deburring, as well as for more aggressive cutting operations such as reaming and tapping. For more challenging materials, such as hardened steels and titanium, more advanced abrasive structures, such as bonded diamond wheels, can be used in order to obtain the desired finish.
In conclusion, cutting difficult-to-process metal materials poses a challenge for engineers. The difficulty in processing these materials tends to result from the need to machine materials with an extremely hard surface. To overcome this challenge, it is important to utilize specialized cutting tools, adjust the cutting speed, feed rate and cutting force, and to select the right abrasive. Following these steps can help to reduce tool wear, improve cut quality, and increase the longevity of the tools used.
