Wodenco Indexable Inserts

I. Indexable Inserts

Indexable inserts refer to a kind of inserts which are mechanically clamped on the cutter body, and when the cutting edge is blunt, indexed inserts without being re-sharpen.

II. Advantages of Indexable Inserts

1) Because machine tool operators no longer sharpen their inserts, this will greatly reduce auxiliary time such as stoppages for inserts change, and improve production efficiency.

2) Because the inserts avoid defects caused by high temperatures in welding and sharpening, the geometric parameters of the tool are completely guaranteed by the insert and the insert holder, which makes the cutting performance stable, thereby increasing the tool life.

3) Because the insert holder has a long service life, it greatly reduces the consumption and inventory of the insert holder, thereby simplifying the management of the tool and reducing the cost of the tool.

4) After the insert is rotated or replaced with a new one, the change of the insert tip shall be within the allowable range of the work piece precision.

5) The insert becomes an independent functional element, and its cutting performance has been expanded and improved.

6) The mechanical clamping type avoids the influence and limitation of the welding process, facilitates the selection of inserts of various materials according to the processing object, and fully exerts its cutting performance, thereby improving the cutting efficiency.

7) The space position of the cutting edge is fixed relative to the cutter body, which saves the auxiliary time needed for changing and matching the cutter, and improves the utilization rate of the machine tool.

III. Indexable Inserts Knowledge:

1) The cemented carbide indexable insert is made by mixing tungsten and cobalt powder in a certain proportion, then pressing with a mold and sending it to a high-temperature furnace for sintering. Coating directly for rough machining, and coating after grinding for finishing.

2) The components of the tool coating are complex. There are two main components: aluminum oxide (Al2O3) and titanium nitride (TIN).

Aluminum oxide (Al2O3) coating is used for wear resistance and titanium nitride (TIN) coating is used for collapse resistance.

3) In our company, more than 90% of all indexable inserts are coated cemented carbide inserts. Inserts that are only partially ceramic or cermet are usually not coated.

IV. There are many types of indexable insert materials, which can be divided into the following 6 types.

1) Cemented carbide Inserts

2) Coated cemented carbide Inserts

3) Cermet Inserts

4) Ceramic Inserts

5) CBN Inserts (more for turning)

6) PCD Inserts

V. Tips for selecting commonly used machine-clamped indexable inserts

 Indexable insert is a kind of machine tool component which is widely used in the process of lathe processing. It is widely used in the field of precision machining. Compared with the traditional insert, indexable insert has more advantages.

First of all, due to the fine workmanship, indexable inserts can avoid the defects of cracks in cemented carbide brazing. Secondly, the manufacturing process of indexable inserts is relatively advanced. According to different processing needs, more materials can be added to the insert, so as to improve the physical and chemical properties of the indexable insert, to adapt to different processing needs. For example, the indexable insert can use vapor deposition to deposit a thin layer of harder materials such as titanium carbide, titanium nitride, and aluminum oxide on the surface of the cemented carbide insert to increase the hardness of the insert, thereby improving the cutting performance of the insert. Finally, due to the indexable inserts are produced in a standardized and centralized production method, we have a good grasp of the control of the insert parameters, which makes the inserts applicable to more precise workpiece processing.

The production technology of the indexable insert is relatively advanced, and it can be made into various shapes, so that the indexable insert has a wider application range. The more common insert shapes currently include regular triangles, quadrilaterals, pentagons, convex triangles, circles, and diamonds. The inserts of these shapes can be adapted to different processing conditions. Technicians can select different inserts to process the workpiece in accordance with different processing requirements.

Indexable inserts are widely used in the field of lathe processing. Indexable inserts have strict material and performance classification, which can meet different processing needs. The processing performance of indexable inserts can be divided according to the material and hardness of the processed material.

• Steel part, Class P, which include: Easy to Machine Steel and Low Carbon Steel, Medium and High Carbon Steel, Alloy Steel and Easy Machining tool Steel, Tool and Die Steel.
• Stainless steel part, Type M, which include: Ferrite and Martensite, Austenite, Precipitation Dispersion Hardening Steel and Bidirectional Steel.
• Cast iron casting, Class K, which include: Gray H Cast Iron, Ductile Iron, Malleable Iron.
• Heat resistant metal parts, Class S, which include: Iron Base Alloy, Nickel Base and Cobalt Base Alloy, Titanium Alloy.
• Aluminum alloys and non-ferrous metals, Class N, which include: Aluminum Alloy, Non-ferrous Metal (Precious Metal, Bronze, Brass Alloy, Magnesium Alloy, Plastic).
• Super hard materials, Class H, which include: Steel after Heat Treatment, Tool Steel after Heat Treatment, Chilled Cast Iron, High Nickel Cast Iron.

According to the order of P, M, K, S, N, H, the processing performance of the above materials increase in turn. Technicians select the material of the corresponding indexable inserts according to the characteristics of their workpieces. For workpieces with harder materials to be processed, carbide, coating materials, ceramic materials, diamond, cubic boron nitride and other materials can be used.

Tips for selecting commonly used machine-clamped indexable inserts: The selection principle is mainly based on the specific conditions of the processing technology. Generally, the insert with higher versatility and more cutting edges on the same insert shall be selected. Larger size is selected for rough turning, and smaller size is selected for fine and semi fine turning.

S shape: It has four cutting edges with short cutting edge (referring to the same diameter of inscribed circle) and high strength of tool tip. It is mainly used for 75 ° and 45 ° turning tools and for machining through holes in internal hole cutters.

T shape: Three edge, longer edge, low strength of the tip. It is often used for the ordinary lathe with a vice angle of the insert to improve the strength of the point. It is mainly used for 90 ° turning tools. and for processing blind hole and step hole in internal hole cutters.

C shape: There are two kinds of nose angle. The strength of the two insert tips with 100 ° nose angle is high. Generally, it is made into 75 ° turning tool for rough turning of outer circle and end face. The two cutting edges of the 80° nose angle have high strength. They can be used to machine end faces or cylindrical faces without changing the tool. Generally, they are used to process stepped holes in internal turning tools.

R shape: Circular cutting edge. It is mainly used for machining special circular arc surface. Its insert utilization rate is high, but the radial force is large.

W shape: The cutting edge of the lathe is 80 ° and the cutting edge is shorter than that of the common cutting edge.

D shape: Two longer cutting edges. The tip angle is 55°. The tip strength is low. It is mainly used for profiling processing. When made into a 93° turning tool, the cutting angle shall not be greater than 27°~30°. When made into a 62.5 ° turning tool, the cutting angle shall not be greater than 57 °~60 °. It can be used for step hole and shallow back cleaning in the inner hole machining process.

V shape: Two long cutting edges. The tip angle is 35 ° angle. Low strength. It is used for profiling. When made into a 93 ° turning tool, the cutting angle shall not be greater than 50 °. When made into a 72.5 ° turning tool, the cutting angle shall not be greater than 70 °. When made into a 107.5 ° turning tool, the cutting angle shall not be greater than 35 °.

Common Q-shaped insert

A cut off inserts with a chip breaker groove.

Cut off Inserts and Grooving Inserts:

Cut off Inserts: Q-shaped inserts are commonly used on ordinary lathes, which can be re sharpen, and the price is generally 2 to 3 CNY/Piece, lower than that of indexable turning tool inserts. The disadvantage of the Q-shaped insert is that the cutting edge is straight and cannot cause the chips to shrink and deform laterally, so it is easy to rub against the machined surface. In addition, its slip angle and side clearance angle are very small, so the cutting heat is high and it is easy to wear. When in use, the cutting edge shall be observed at any time, and the insert shall be re-sharpened or replaced in time. On CNC lathes, a cutt off insert that directly presses the chip breaker groove is generally used. It can cause the chips to shrink and deform laterally, cutting briskly, and reliable chip breaking. In addition, its slip angle and side clearance angle are large, the cutting heat is less, and the service life is longer, but the price is higher.

Grooving inserts: General cutting inserts for deep grooves and shaping inserts for shallow grooves, such as the following types: vertical grooving inserts, flat grooving inserts, strip grooving inserts, clear step circular arc root groove inserts. The groove width cut by these inserts has high precision.

Threaded inserts: The commonly used threaded insert is L-shaped, which can be re sharpen. It’s cheap, but it can’t incisor the crest. The cutting precision of a insert with a thread form is higher. According to the different sizes of thread form of internal and external threads, they can be divided into internal and external threaded inserts. Its thread pitch is fixed and the crest can be cut out. According to the clamping method, it is divided into two types: one is the insert with no holes and the upper pressure clamping insert. This kind of insert needs to add a chip plate when processing higher plastic materials. The other is an insert that presses out the chip slot and has a clamping hole, which is clamped by a pressing hole type Torx screw.

Cutting edge length: It shall be selected according to the back cutting depth. Generally, the cutting edge length of the slotted insert shall be ≥ 1.5 times of the back cutting depth, and that of the closed groove insert shall be ≥ 2 times of the back cutting depth.

Insert tip arc: When rough turning, as long as the rigidity allows, use a larger insert tip arc radius as much as possible. When finishing turning, generally use a smaller arc radius. However, when rigidity allows, it shall be selected from a larger value. The circle radius of common pressing molding is 0.4, 0.8, 1.2, 2.4 and so on.

Insert thickness: The selection principle of the insert thickness is to make the insert have enough strength to withstand the cutting force. It is usually selected according to the amount of back feed and feed. For example, some ceramic inserts require thicker inserts.

Normal clearance of insert: The commonly used normal clearance of inserts are: 0° (code N), 5° (code B), 7° (code C), 11° (code P). Generally, 0° is used for rough and semi-finished turning. 5°; 7°; 11° for semi-finishing, finishing turning, profiling and machining inner holes.

Insert precision: According to national regulations, indexable inserts have 16 precisions, of which 6 are suitable for turning tools, and the codes are H, E, G, M, N, U. H is the highest and U is the lowest. General lathes use U grade for rough and semi-finish machining, M for CNC lathes that require higher tool tip position, and G for more advanced lathes.

VI. Factors affecting the selection of indexable inserts

The primary factor affecting the selection of indexable inserts is the material to be processed, so the indexable inserts shall be selected according to the material of the processed materials. In addition, the processing environment shall also be considered. With the continuous development of machine tool processing technology, the processing of workpieces is not limited to traditional work piece processing, and is developing in the direction of integration of workpiece manufacturing and processing. This makes indexable tools to adapt to more varied and complex machining environments. The insert shall meet the requirements for workpiece processing in a special environment. For example, the workpiece should be high temperature resistant, have higher hardness, but also have toughness, wear resistance, thermal conductivity, chemical inertia. The cutting tool shall have strong machinability, conform to the standard, cutting control function. Therefore, the reasonable choice of the indexable insert is a very important issue for engineers and technicians.

Welcome to know the detailed parameters of WODENCO Indexable Inserts, please feel free to contact us today!

VII. Negative Angle Indexable Inserts With Hole Detail Information

VIII. Positive Angle Indexable Inserts With Chip Breaker Groove detail information