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GREEN CARBIDE

Tungsten

Reduce scrap rate, eliminate breakage, reduce your cost per part.

Tungsten Carbide is widely used in wear and die applications. Preforms often require intricate shapes and precisely shaped holes and are shaped while still in the green as-pressed form or after pre-sintering to increase part strength. In both cases, carbide powder rapidly wears conventional carbide tooling. Edge wear creates additional cutting force that can damage the parts being produced. One way to eliminate this damage to parts is to presinter the carbide preforms before drilling, and then grinding away .030in of the surface layer following drilling operations. This procedure helps prevent ‘blowout’ or ‘flaking’ around the hole during the sintering process due to the stresses produced by drilling the powder with worn cutting edges.
Precise hole depth and location in preforms requires the scrapping of  one or two parts in order to ensure that holes are drilled in the desired locations. Frequent resharpening of conventional carbide drills required  that the setup be re-verified and adjustments to be made for each drill length. PCD drills, lasting 50 to 100 times longer than carbide drills, made a single setup possible.

Basic Carbide Corporation, Buena Vista, Pennsylvania found an additional benefit from using Precorps DiaEdge drills. Scrap rates were greatly reduced. Reducing cutting forces made it possible to drill a .061 in (1.55mm) blind hole over 4.6 in (116mm) deep in a relatively delicate green carbide preform. With carbide drills, it was not uncommon to break more than half of the preforms due to the rapid dulling of the drills cutting edges. DiaEdge twist drills eliminated preform breakage resulting in a substantially lower cost per part produced.

As a general rule, replacing tungsten carbide tooling with PCD in nonferrous applications yields an eight fold reduction in tool cost per piece produced.

As a general rule, replacing tungsten carbide tooling with PCD in nonferrous applications yields an eight fold reduction in tool cost per piece produced. However, the biggest gain comes from the decreased downtime associated with tool changes.  One company found that a tool change was required after just four holes using conventional drills. Between each tool change the operator needed to resharpen the drill, and adjust his setup to account for the new drill length. Switching to DiaEdge twist drills allowed and entire lot of 100 parts to be finished with a single drill. This cut the time required to finish the job by more than half.

PCD twist drills provide producers of tungsten carbide die and wear parts with a new tool to tackle numerous shapes and forms. As a bonus, tool costs can be sharply reduced, along with significant gains in labor productivity.