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What Is Whisker-Reinforced Ceramic? Whisker-reinforced ceramic as applied to cutting tool inserts comprises a matrix of aluminum oxide into which approximately 50% by volume of high-purity silicon carbide "whiskers" are randomly dispersed. The "whiskers" are, in fact, single crystals having dimensions of approximately 0.6 microns in diameter x 10-80 microns in length. These "whiskers" have a tensile strength on the order of 1,000,000 psi (690 MPa). The composite material that is the best known and most widely applied using this technology is designated WG-300 and manufactured by the Greenleaf Corporation of Saegertown, PA.
Indexable carbide insert (ICI) cutting tools continue to play a pivotal role in gear manufacturing. By offering higher cutting speeds, reduced cycle times, enhanced coatings, custom configurations and a diverse range of sizes and capabilities, ICI tools have proven invaluable for finishing and pre-grind applications. They continue to expand their unique capabilities and worth in the cutting tool market.
Recently, a new type of hob with carbide inserts has been introduced, providing higher cutting speeds, longer tool life and higher feed rates when compared to re-grindable, high-speed steel hobs. But with this kind of hob, new challenges occur due to positional errors of the cutting edges when mounted on the tool. These errors lead to manufacturing errors on the gear teeth which must be controlled. In this paper, the tooth quality of a gear manufactured by hobs with different quality classes is analyzed using a simulation model in combination with Monte Carlo methods.
Hobs, broaches, shaper cutters, shaver cutters, milling cutters, and bevel cutters used in the manufacture of gears are commonly made of high speed steel. These specialized gear cutting tools often require properties, such as toughness or manufacturability, that are difficult to achieve with carbide, despite the developments in carbide cutting tools for end mills, milling cutters, and tool inserts.
Decades ago, technology shifted from HSS to indexable inserts in turning and milling. This movement wasn't immediately realized in gear hobbing because coated PM-HSS hobs and complex gear profiles remained highly effective and productive methods. Only fairly recently have gear manufacturers started to take a serious look at indexable technology to cut gear teeth.
News Items About inserts
1 Sandvik Introduces New Turning Inserts (January 5, 2012)
March 1st 2012 sees the introduction of a new range of turning inserts from Sandvik Coromant. Spectrum turning is a minimum program that ... Read News
2 Techniks Introduces Nexus Cutting Tool Inserts (November 5, 2012)
Nexus Cutting Tools—a new product line from Techniks—introduces its new line of Lamina cutting inserts, unveiled at IMTS 2012... Read News
3 Walter USA Introduces Ceramic Inserts (December 7, 2012)
Walter USA, LLC has introduced a new series of ceramic inserts directed at machining high-temp alloys such as Inconel, Waspalloy and Stel... Read News
4 Sumitomos New Inserts Feature Six Cutting Edges (April 22, 2006)
Sumitomo Electrics new 55 degree SumiTurn T-REX triangle insert was launched as a replacement for the 55 degree DNMG. The T-REX fea... Read News
5 High-Speed Inserts Incorporate Through Coolant (June 11, 2010)
The Power-Feed+Mini high feed cutter from Ingersoll Cutting Tools features high-speed geometry with a double-sided, four-edge insert engi... Read News
6 Walter Releases Cutting Tool Inserts (December 27, 2012)
Walter USA, LLC has announced that its Tiger•tec Silver for Turning product line has fielded four new cutting tool insert geometries... Read News