In many cases, it's a benefit because the flaking, almost like chipping flint, exposes a new sharper edge.". In an increasing number of applications, the right tools for the jobs are ceramic cutters. A breakdown of the composition of Macor is as follows: Precision Ceramics is your Macor machinable glass specialist for your technical ceramic prototyping & manufacturing needs; we are always happy to use our many years of advanced ceramics experience to provide advice on materials, design, and application. Every insert has a melting point, which reflects the temperature at which it is made. An alternative is a silicon Always use water cooling when grinding Macor. Many of the inherent cutting advantages of the grinding process—high heat tolerance, excellent surface finish, long tool life—transfer to milling and turning operations with the application of ceramic inserts. Typical head speeds are 1000–1500 rpm with a chip load of 0.05mm per tooth. While available as solid body tools, the most popular form of ceramic cutters is the indexable ceramic insert. Feed Rate = 0.005-0.013 cm/rev (.002-.005 ipr)Depth of cut = 0.38-0.65 cm(.150-.200 in). The heat dissipation objective for most carbide cutting inserts is to get heat into the chip and quickly out of the cut zone. Milling Speeds and Feeds Charts. In roughing operations, where surface finish is not a critical concern, this type of tool wear is generally not a concern. Milling in ceramic (Macor) hubihubi2 (Bioengineer) (OP) 2 Nov 13 17:07. Therefore in milling operations, each insert must travel faster to generate the heat equivalent of a single point turning tool. "Flaking off of small pieces around the top periphery of the insert is a result of pressures caused by flank wear. Almost every shop uses indexable inserts. When first machining Macor, try using lower machine speeds and smaller cut depths as this will help keep the piece cool, reduce the potential of chipping, and lead to overall the better results. While much research has been conducted to describe the dynamics of chip formation, one common factor found in all of the theories is that much heat and stress gets generated as a cutting tool displaces the metal. These crystals are like fibers and act as reinforcement to the brittle ceramic. "Coolant volume is more important than pressure in ceramic cutting applications," says Mr. Smith. of Teeth and the Chip Load per Tooth to Determine the Feed Rate (In./Min.) In addition to an appreciation of the basic properties of nickel alloys them-selves, of paramount importance to successful machining is an understanding Depths of cut are as for turning. Use .002-.005 as starting chip load per tooth The biggest difference between the two cutting tools is that the insert is manufactured without the porosity necessary for grinding. For drill holes up to 5mm a spindle speed between 1000 & 1500 and a feed rate of 20 to 30 mm/min has shown the best results. In this article we will concentrate on ceramic inserts that use silicon carbide crystals to reinforce the base ceramic compound. In roughing, for example, use a large radius to rough the workpiece and then finish with a smaller tool nose radius. To find out more about ceramic inserts and especially how their application in metalworking differs from carbide inserts, we talked to Keith Smith, manager marketing and international sales for Greenleaf Corporation (Saegertown, Pennsylvania). Climb milling prevents material being pulled off the edge of the MACOR®. Another depth-of-cut strategy for flat-sided ceramic inserts is to program fewer passes but deeper ones in order to bury the insert deeper in the workpiece. Varying the depth spreads the wear patterns over a larger section of the insert. Understanding the right speeds and feeds for your tool and oper… Likewise there are different kinds of ceramics. Simple process considerations can increase your productivity in milling titanium alloys. Because heat cannot be transferred ahead of the cutter, in effect, to anneal the already hardened workpiece, cutting forces become too high and insert failure occurs. Among carbide indexable inserts there is a huge selection of shapes, substrates, coatings and geometries from which to choose. Cutting with ceramic tools puts a strain on the machine tool. Calculate Speed and Feed for Turning Applications. Calculate the circumference of the workpiece then subtract the sum total of interruptions. A major difference is the way ceramics use heat generated in the cut. Ceramic cutters in many cases demand a new set of application skills from the shop looking to implement them. Probably the major down side of the ceramic insert is its brittleness. In effect this calculation gives a smaller diameter. Silicon Carbide and Alumina grinding wheels (grade 36 or finer) can be used. There's an axiom in metalworking that urges the use of the right tool for the job. A dull tool will lead to more chipping. A 0.5μin.-AA finish can be achieved. It's bad for the tool and generally bad for the workpiece (work hardening). The crystals that compose Macor are very small, meaning that a very good surface finish can be achieved even without additional polishing or lapping.

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