About Tungsten Carbide F1. brazed plates made of Tungsten Carbide materialTungsten Carbide, also known as Cemented Carbide, is an alloy of tungsten and carbon.  It is a metal-like substance and is approximately 2 to 3 times as rigid and dense as steel.  Tungsten Carbide is often referred to as a Hard Metal, since it possesses very high hardness in relation to other metals.  The Mohs hardness rating of Tungsten Carbide is around 8.5 ~ 9, and it is an extremely stable substance which does not oxidize under normal temperatures and keeps its stable characteristics even in severe environments.Tungsten Carbide’s hardness and resistance to heat make it an ideal material for cutting tools and high-performance wear parts to be used in the environments under high temperature and high speed.  Due to its exceptional hardness and wear resistance, Tungsten Carbide has a wide range of application in many industry sectors such as metal machining, wear parts for mining, metal forming tools, cutting tips for saw blades, etc.   How Tungsten Carbide Machining Works? Owing to the extremely high hardness of Tungsten Carbide, it is impossible to be machined by traditional machining process such as turning, milling, or drilling.  Though it can be machined by special tools, including PCD, CNB, and ceramic tools, these cutting tools will easily wear out and lose the sharpness.F2. metal material grinding processGenerally, Tungsten Carbide will be grinded with diamond tools or machined by electrical discharge machining (EDM).  Though Tungsten Carbide is machinable by using these machining methods, the machining process is destined to face multiple difficulties and challenges.   Difficulties in Tungsten Carbide Machining Tungsten Carbide Machining Challenges in Quality and Tool LifeTungsten Carbide is incredibly hard and difficult to machine.  Its hardness and brittleness make it easily cracked or chipped during the machining process, and it also chips the cutting tools very easily.  Generally, it is impossible to be machined by traditional machining process.  Though it can be machined by special tools, such as PCD, CNB, and ceramic tools, these cutting tools lose their sharpness easily.F3. carbide cutting tools for industrial applications Tungsten Carbide Machining Challenges in EfficiencyThe control of vibration and cutting force is extremely important to machining Tungsten Carbide, in virtue of its high density, rigidity, and brittleness.  If the vibration and cutting force are not well-controlled, it is very subject to micro cracks and fragmentation.  Therefore, the machining process is often extremely time-consuming and has constantly been tormenting the processing manufacturers when dealing with this material.   What Does HIT Ultrasonic Machining Bring to Tungsten Carbide Machining? F4. Tungsten Carbide machining processHIT’s ultrasonic-assisted machining technology provides the superimposition of the tool rotation with a high-frequency oscillation in longitudinal direction, generating over 20,000 times of micro-vibration per second.  The mechanism helps reduce cutting forces and facilitates chip removal process.F5. HIT's ultrasonic machining technology with high-frequency oscillation in longitudinal direction facilitates chip removal processThe reduction in cutting forces not only decreases frictions between tools and workpieces, but also allows feed rates to be increased.  This greatly improves the quality of workpieces and the stability of tool life, and saves quite an amount of processing time.F6. HIT's ultrasonic machining technology helps reduction in cutting force, bringing more stability in tool lifeFacilitating chip removal process diminishes frictions on both tools and workpieces caused by excessive amount of chips.  HIT’s ultrasonic high-frequency micro-vibration allows chips to break easily and lessens the occurrences of entangled chips.  This also displays a great benefit to both the quality of workpieces and the stability of tool life.More information on HIT Ultrasonic Machining Technology   Two Successful HIT Cases of Tungsten Carbide Machining Tungsten Carbide Machining Case 1 : (Slot) Trochoidal MillingF7. Tungsten Carbide ultrasonic-assisted (slot) trochoidal milling workpieceWith HIT ultrasonic, the high frequency micro-vibration allows the tool to constantly lift from workpiece.  This brings better inflow of cutting fluid, offering better cooling effect and easier chip and carbonized diamond powder evacuation.F8. HIT ultrasonic-assisted slot trochoidal milling of tungsten carbide achieved better surface qualityUnder the same cutting parameters, with HIT ultrasonic, it helped reduce the surface roughness of the slots.  There was no obvious tool marks or scratches left on the surface compared to that without ultrasonic.F9. HIT ultrasonic-assisted slot trochoidal milling of tungsten carbide brought better chip evacuation, preventing chips or carbonized diamond powder stuck on the toolBetter chip and carbonized diamond powder evacuation helps reduce friction between tool and workpiece, which then reduces the cutting forces.  This not only prolongs the tool life, but also helps enhance over 2x higher material removal volume.More information on Tungsten Carbide: (Slot) Trochoidal Milling Tungsten Carbide Machining Case 2 : Threading & GrindingF10. Tungsten Carbide threading & grinding workpiece HIT carried out threading (M10x1.5P) and grinding (h-shape) on a 50x70x10mm Tungsten Carbide workpiece.  Using HIT’s ultrasonic tool holder HSKA63 with the integration of CTS, ATC, and CNC automation system, HIT completed the entire machining process within 5 hours, compared to over 12 hours by the traditional EDM process.  The surface roughness of the h-shape grinding went from Ra > 0.8μm to the average of Ra < 0.1μm.This feature is widely applied in the Precision Machinery industry, especially being used for Tungsten Carbide molds and punches.More information on Tungsten Carbide : Threading & Grinding   Tungsten Carbide Machining FAQ   Q1  How do I know the tools I used to machine Tungsten Carbide can be fitted into HIT’s ultrasonic machining module system?A1  HIT’s ultrasonic machining module has the ability to automatically scan for the proper frequency of the corresponding tool (within the standard frequency range of 20 – 32kHz).  The system can even further adjust the frequency range, depending on specific tools used by the clients.  Over the years, most of the tools in general have been validated to be available for HIT’s ultrasonic machining module system.F11. HIT ultrasonic machining driver moduleMore information on HIT Ultrasonic Machining Module Q2  How to adjust feed rates and amplitude when I start machining Tungsten Carbide with HIT’s ultrasonic machining module system?A2  HIT aims to help clients face the challenges in Tungsten Carbide machining.  This includes providing the optimum machining parameters and services to ensure clients having the best experiences in using HIT’s ultrasonic machining module system.  It is not just buying a product from HIT, but obtaining the knowledge, services, and efforts from the most professional team.F12. HIT ultrasonic tool holders  Tungsten Carbide Machining?  Choose HIT Contact us if you are looking for a better way to improve machining efficiency, quality, and tool life.

 About Titanium and its Common Use  Titanium Material PropertiesTitanium alloys are metals composed of a mixture of titanium and other chemical elements.  The most common form of titanium alloys is Ti-6Al-4V (Learn more about the crystallographic forms of Titanium Alloys).  The Mohs hardness ranking of this form of titanium alloy is approximately 41HRC, which is not as hard compared to other metal alloys.  This material offers a combination of lightweight, high strength, low density, good corrosion resistance and ductility. F1. titanium metal alloy materialTitanium alloys are also recognized for their exceptional resistance to a wide range of chemical environments provided by a thin, invisible but extremely protective surface oxide film.  The absorption of oxygen into the surface when the material is heated will cause an increase in hardness of the surface layer (Learn more about work hardening of Titanium Alloys). Common Applications of TitaniumIts excellent material properties, including lightweight, high strength, good corrosion resistance and good ductility, make it the prime choice for many fields of applications, including aircraft turbines, engine components, aircraft structural components (wings and fuselage), aerospace fasteners, automotive components (body panels, valves), marine applications, etc. F2. bolts and engine parts made of titanium alloyAerospace applications still account for the biggest chunk of the use of titanium alloys, due to its fine material properties of high strength, good fatigue resistance and fracture toughness.F3. Boeing 757-200 jet engine application in aerospace industry   Tips and Common Tools for Titanium Drilling Titanium alloys require well-setup machining process to prevent the material from bending or surface hardening due to its low density, good ductility, and work hardening properties.  Generally, the tool should be maintained as sharp as possible to minimize the built-up heat and tool wear.  Using rigid setups between tool and workpiece to prevent the workpiece from bending due to its ductile characteristic.  Proper cooling device is also strongly advised to lower the built-up heat.F4. drilling titanium alloy requires sharp and rigid drillsWhen it comes to drilling titanium alloys, carbide drills are the best choice especially for deep hole drilling.  Using sharp drills of proper geometry and avoiding having the drill ride through the titanium surface are also key to successful drilling on titanium alloys (Learn more about tips on successful drilling on Titanium Alloys).   Difficulties in Titanium Drilling  Titanium Drilling Challenges in QualityThe good ductility and work hardening properties of titanium alloys have brought serious concerns for the quality of hole wall and the positional precision of the drilling holes.  If the cutting (drilling) force is not well-controlled, the workpiece may suffer from displacement due to its ductile property.  Its hardened surface and entangled chips will also cause severe damages to both the quality of workpiece and its positional precision.  When it comes to higher aspect ratio (hole depth to diameter), it is going to be even more challenging to maintain the quality. Titanium Drilling Challenges in Tool LifeThe work hardening property of titanium alloys when it is heated has brought huge difficulties in drilling this material.  With the protective oxide layer on the surface of titanium alloys, the drills may lose their sharpness easily and even encounter risks of tool breakage.  Along with the entangled chips produced in the drilling process, not only the quality of workpiece is at stake, but also the tool life will be disastrously unstable.  The major challenge also lies in controlling the cutting (drilling) force in the drilling process.F5. drilling process on a CNC machine   HIT Achievements in Titanium Drilling HIT’s ultrasonic-assisted machining technology provides the superimposition of the tool rotation with a high-frequency oscillation in longitudinal direction, generating over 20,000 times of micro-vibration per second.  The mechanism helps reduce cutting forces and facilitates chip removal process. F6. HIT's ultrasonic machining technology with high-frequency oscillation in longitudinal direction facilitates chip removal processThe reduction in cutting forces not only decreases frictions between tools and workpieces, but also allows feed rates to be increased.  This mechanism along with the high pressure (70bar) coolant through spindle (CTS) feature help lower the heat produced during the machining process.  This greatly improves the quality of workpieces and the stability of tool life, and saves a huge amount of processing time.F7. HIT's ultrasonic machining technology helps reduction in cutting force, bringing more stability in tool lifeFacilitating chip removal process diminishes frictions on both tools and workpieces caused by excessive amount of chips.  HIT’s ultrasonic high-frequency micro-vibration allows chips to break easily and lessens the occurrences of entangled chips.  This also displays a great benefit to both the quality of workpieces and the stability of tool life.Drilling titanium alloys with ultrasonic-assisted machining technology, the reduction in cutting forces and improvement in chip removal process allow better control of the quality of workpieces and the stability in tool life.More information on HIT Ultrasonic Machining Technology   Two Successful HIT Cases of Titanium Drilling  Titanium Drilling Case 1 : Micro-DrillingF8. titanium alloy micro-drilling workpieceHIT discovered that conducting the Φ0.5x5mm micro-drilling 50 holes on titanium alloy (Ti-6Al-4V) with ultrasonic-assisted machining technology, the cutting force can be reduced by 39%.  With the integration of CTS, it greatly reduced the occurrence of twisted or entangled chips.  This not only prolonged tool life, but also maintained the positional precision of the micro-holes.F9. shape of chips in titanium alloy micro-drillingThis feature is widely applied in the Aerospace industry and the 3C Electronics industry, especially being used for aircraft riveted components, phone cases, etc.More information on Titanium Drilling : Micro-Drilling Titanium Machining Case 2 : Side MillingF10. titanium alloy side milling workpieceHIT carried out side milling on titanium alloy (Ti-6Al-4V).  Using HIT’s ultrasonic tool holder BT30 with the integration of CTS, ATC, and CNC automation system, HIT managed to greatly improve the tool life.  It only showed a minor broken corner on the rake face of the tool, instead of severe tool wear such as the exposure of coating grains.F11. rake face of the tool in titanium alloy side millingF12. shape of chips in titanium alloy side millingThis feature is widely applied in the Aerospace industry and 3C Electronics industry, especially being used for aircraft structural components, phone cases, etc.   Titanium Drilling FAQ  Q1  How to control the cutting (drilling) force while reaching the required quality of the drilling holes?A1  HIT’s ultrasonic-assisted machining technology provides the superimposition of the tool rotation with a high-frequency oscillation in longitudinal direction, generating over 20,000 times of micro-vibration per second.  The mechanism helps reduce cutting forces and facilitates chip removal process.  HIT’s ultrasonic high-frequency micro-vibration allows chips to break easily and lessens the occurrences of entangled chips.  With the assistance of high pressure (70bar) coolant through spindle (CTS), it allows the chip removal process even smoother.  These features can successfully bring better quality of the workpieces and longer, more stable tool life.F13. HIT ultrasonic machining driver moduleMore information on HIT Ultrasonic Machining Module Q2  How to adjust feed rates and amplitude when I start drilling titanium alloys with HIT’s ultrasonic machining module system?A2  HIT aims to help clients face the challenges in drilling titanium alloys.  This includes providing the optimum machining parameters and services to ensure clients having the best experiences in using HIT’s ultrasonic machining module system.  It is not just buying a product from HIT, but obtaining the knowledge, services, and efforts from the most professional team.F14. HIT ultrasonic tool holders  Titanium Drilling?  Choose HIT Contact us if you are looking for a better way to improve machining efficiency, quality, and tool life.