Trumpf introduces its Highspeed and Highspeed Eco nozzles, which are designed to boost feed rate for solid-state laser machines that employ fusion cutting with nitrogen. The nozzles are said to increase the speed of the piercing process without increasing laser power, and enable an increase in sheet throughput over standard cutting. The Highspeed nozzle is said to use 40 percent less nitrogen gas and the Highspeed Eco Carbide Grooving Inserts is said to use 70 percent less nitrogen gas to blow molten material out of the kerf without needing to rework oxidized cut edges, enabling cost savings.
The nozzles are bi-flow, with some of the cutting gas passing through the center of the nozzle with the laser beam, and the rest of the gas forming a secondary flow around the principle flow to concentrate it onto the kerf, expelling molten material. The nozzles are fitted with a sleeve that is designed to glide across the material during cutting, forcing gas directly into the kerf and minimizing gas flowing off to the side while keeping the nozzle 0.06" from the sheet surface. The nozzle is designed to withstand spatter generated during piercing, accelerating piercing and minimizing the risk of damage.
The nozzles are capable of fusion cutting of 0.5"-thick sheets, instead of 0.4"-thick sheets as in the past. The nozzles can cut mild-steel and stainless-steel Shoulder Milling Inserts sheets at least 0.16" thick. Because the nozzles can cut a range of material thicknesses, mix-ups and setup times are reduced. Cut edges are said to exhibit low surface roughness and a consistent look.
Nozzles are available for the TruLaser Series 5000 equipped with an 8-kW solid-state laser and will be available for 6-kW solid-state lasers. Many relatively new machines can be retrofitted with these processes.
The Carbide Inserts Website: https://www.estoolcarbide.com/cutting-inserts/
Allied Machine and Engineering displays its newest addition to the T-A Pro high-penetration drilling system — the M geometry insert — at IMTS in booth #431436 in the West Hall. With the release of the ISO-material class M geometry, targeting stainless steel and high-temp super alloy (HRSA) materials, and proprietary margin design paired with the development of the new AM460 coating, Allied Machine says it is able to provide a tool that offers low cutting forces, excellent penetration rates and long tool life SNMG Insert in challenging stainless high-temp super alloys. The new insert geometry produces ideal results with the newly designed T-A Pro holders, the company notes, but is also compatible with T-A holders.
When asked for the single most important feature of this technology for a mold builder, Allied Machine points to the insert’s geometry with proprietary margin reliefs, which is said to significantly reduce the amount of heat around the outside diameter of the cut. It also provides a simple drilling solution for an otherwise difficult-to-machine material group like stainless steel, which moldmakers often use for either corrosion resistance or for medical-grade use.
In addition, the T-A Pro M geometry’s design elements enable for larger diameters — 1" and above — to ANKT Indexable Insert be used on smaller or under-powered machines where additional setups on other machine tools would be needed, or where parts would need to be contracted out. The ability to run high speeds and light feeds gives additional flexibility.
The Carbide Inserts Website: https://www.estoolcarbide.com/lathe-inserts/rcmx-insert/
PCD dies, also known as Polycrystalline Diamond dies, are specialized tools used in the wire drawing process. Wire drawing is a manufacturing technique that involves Carbide Drilling Inserts pulling a metal wire through a die to reduce its diameter and improve its shape and surface finish.
PCD dies are made from a synthetic diamond material known as polycrystalline diamond. This material is created by sintering together diamond particles under high pressure and temperature, resulting in a dense and extremely hard structure. PCD dies offer superior wear resistance and hardness compared to traditional wire drawing dies made from other materials.
The main advantages of PCD dies include:
Wear resistance: PCD dies have excellent resistance to wear, allowing them to withstand the high pressures and abrasion encountered during the wire drawing process. This leads to longer die life and reduced downtime for die replacements.
Surface finish: PCD dies produce wire with a smooth surface finish and tight dimensional tolerances. This is crucial for applications where the wire needs to meet specific requirements for quality and precision.
Extended tool life: Due to their exceptional hardness and wear resistance, PCD dies have a longer tool life compared to other types of wire drawing dies. This translates to cost savings and increased productivity.
Material compatibility: PCD dies can be used with a wide range of materials, including non-ferrous metals like copper, aluminum, and brass, as well as certain ferrous materials.
PCD dies are available in various shapes and sizes to accommodate different wire diameters and drawing applications. They SNMG Insert are commonly used in industries such as automotive, aerospace, electronics, and telecommunications, where high-quality wire with precise dimensions is required.
It's worth noting that PCD dies are highly specialized tools, and their manufacturing and maintenance require expertise and specialized equipment.
The choice between a carbide end mill and a milling insert depends on several factors, such as the specific machining operation, the material being machined, and the type of machine tool being used.
Carbide end mills are solid cutting tools that are ideal for a variety of machining operations, such as drilling, slotting, and profiling. They come in various shapes and sizes and can be used for both roughing and finishing operations. Carbide end mills are generally more versatile and can provide greater precision and surface finish compared to milling inserts. They can DCGT Insert also be re-sharpened and re-used, making them more cost-effective over time.
Milling inserts, on the other hand, are indexable cutting tools that are designed to be mounted on a milling cutter body. They are ideal for high-volume cutting operations and can be quickly replaced when worn or damaged. Milling inserts are available in a variety of geometries and grades to suit specific materials and cutting conditions. They are often used for roughing operations, where large amounts of material need to be removed quickly.
Ultimately, the choice between a carbide end mill and a milling insert depends on the specific machining operation and the material being machined. Carbide end mills are more versatile and can provide greater precision and surface finish, while Indexable Milling Insert milling inserts are more suited for high-volume cutting operations.
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The Carbide Inserts Website: https://www.estoolcarbide.com/cutting-inserts/snmg-insert/
Tungsten processing, preparation of the ore for use in various products.
Tungsten exhibits a body-centred cubic (bcc) crystal lattice. It has the highest melting point of all metals, 3,410° C (6,170° F), and it has high conductivity for electricity. Owing to this unique combination of properties, it is used extensively as filaments for incandescent lamps, as electric contacts, and as electron emitters for electronic devices. Tungsten also has found wide application as an alloying element for tool steels and wear-resistant alloys. Tungsten carbides are used for cutting tools and hard-facing materials owing to their hardness and resistance to wear. The metal is brittle at room temperature but ductile and strong at elevated temperatures. Its alloys are employed in rocket-engine nozzles and other aerospace applications.
Tungsten Ores Major minerals of tungsten are essentially of two categories. The first is wolframite [(Fe, Mn)WO4], which contains iron and manganese tungstates in all proportions between 20 and 80 percent of each. The second is scheelite (CaWO4), which fluoresces a bright bluish colour under ultraviolet light.
Tungsten deposits occur in association with metamorphic rocks and granitic igneous rocks. The most important mines are in the Nan Mountains in the Kiangsi, Hunan, and Kwangtung provinces of China, which possesses about 50 Cast Iron Inserts percent of the world’s reserves. In Russia, mines are located in the northern Caucasus and around Lake Baikal. There are also deposits in Kazakhstan. About 90 percent of South Korea’s tungsten is at Sang Dong. Canada’s Northwest Territories is home to the largest tungsten mine in the Western world, and a mine at Chojlla, Bol., is the largest producer in South America. Deposits in the United States are spread along the Rocky Mountains.
Extraction and refining – Ammonium paratungstate
Tungsten ores frequently occur in association with sulfides and arsenides, which can be removed by roasting in air for two to four hours at 800° C (1,450° F). In order to produce ammonium paratungstate (APT), an intermediate compound in production of the pure metal, ores may be decomposed by acid leaching or by the Carbide Threading Inserts autoclave-soda process. In the latter process, the ground ore is maintained for 11/2 to 4 hours in a solution of 10–18 percent sodium carbonate at temperatures of 190° to 230° C (375° to 445° F) and under a pressure of 14.1–24.6 kilograms per square centimetre (200–350 pounds per square inch). Prior to the removal of unreacted gangue by filtration, the acidity is adjusted to pH 9–9.5, and aluminum and manganese sulfates are added at 70°–80° C (160°–175° F) and stirred for one hour. This can eliminate phosphorus and arsenic and reduce silica to a level of 0.03–0.06 percent. Molybdenum is removed by adding sodium sulfide at 80°–85° C (175°–185° F) at a pH of 10, holding for one hour, and then acidifying the solution to pH 2.5–3 and stirring for seven to nine hours to precipitate molybdenum sulfide. The remaining sodium tungstate solution can be further purified by a liquid ion-exchange process, using an organic extractant consisting of 7 percent alamine-336, 7 percent decanol, and 86 percent kerosene. During the countercurrent flow of the extractant through the solution, tungstate ions transfer from the aqueous phase to the organic phase. The tungsten is then stripped from the extractant into an ammonia solution containing ammonium tungstate. The resultant APT solution is sent to an evaporator for crystallization.
In the acid-leaching process, scheelite concentrate is decomposed by hydrochloric acid in the presence of sodium nitrate as an oxidizing agent. This charge is agitated by steam spraying and is maintained at 70° C (160° F) for 12 hours. The resultant slurry, containing tungsten in the form of a solid tungstic acid, is diluted and allowed to settle. The tungstic acid is then dissolved in aqueous ammonia at 60° C (140° F) for two hours under stirring. Calcium from the resulting solution is precipitated as calcium oxalate, while phosphorus and arsenic may be removed by the addition of magnesium oxide, which forms insoluble phosphates and arsenates of ammonium and magnesium. Iron, silica, and similar impurities that form colloidal hydroxides are removed by adding a small amount of activated carbon and digesting for one to two hours. The solution is clarified through pressure filters and evaporated to obtain APT crystals.
