That depends on the application. Factors such as the material to be machined, the load on the tool and the chosen coating play an important role here. In many cases, a different grade or a tool with a coolant channel can help to extend tool life.
Toolmaking industry
Carbide for tools that last longer
The toolmaking industry is placing ever-higher demands on productivity, accuracy and tool life. Tools must be able to handle difficult-to-machine materials, whilst lasting longer and, for some applications, machining faster. This requires materials that can withstand high loads, wear and the heat generated during machining. As a result, carbide is now the standard for many applications. Thanks to the combination of hardness and wear resistance, tools stay sharp for longer and require fewer changes. Furthermore, the heat resistance of cemented carbide enables higher cutting speeds. Cemented carbide also expands relatively little in response to temperature changes, which helps to maintain consistent dimensions during machining.
The benefits of GSE Carbide:
- The widest range of standard lengths (diameter up to 40 mm and length up to 330 mm)
- Personal contact, with technical advice
- Additional grinding operations to your specifications
Why do tool manufacturers choose carbide?
In the toolmaking industry, a great deal revolves around tool life and process reliability. Every tool change takes time. Every unplanned machine downtime affects productivity. That is why manufacturers are constantly looking for ways to extend the tool life of their tools without compromising accuracy.
Carbide offers significant advantages in this regard. The material is harder and more wear-resistant than traditional alternatives such as steel, HSS and PM (powder metallurgical materials). As a result, cutting edges remain sharp for longer, even under demanding machining conditions. Furthermore, carbide retains its properties well at high temperatures. Its relatively low thermal expansion helps to minimise dimensional changes caused by heat. This is particularly important in production processes where components must be manufactured to tight tolerances and with consistent dimensions. This offers several advantages:
- longer tool life;
- fewer tool changes and less machine downtime;
- consistent and higher accuracy;
- greater process reliability;
- better performance at higher cutting speeds.
These benefits can have a significant impact on overall production costs, particularly in batch production.
Common uses of cemented carbide
Carbide is used in the toolmaking industry for a wide range of machining and cutting tools. Many applications start with a carbide rod, which is then machined into a finished product.
Carbide drills
A key application is the production of carbide drills. These are used for the precision machining of a wide range of materials, from steel and aluminium to alloys that are difficult to drill. Depending on the application, drills can be supplied with internal coolant holes. This allows coolant to be delivered close to the cutting edge, enabling heat and chips to be removed more efficiently.
Carbide end mills
Carbide is also frequently used as the base material for end mills. Its high wear resistance enables longer tool life, whilst the dimensional stability of carbide helps to keep the tool’s geometry and dimensions as consistent as possible during use. This is important in milling operations where components need to be produced to tight tolerances. End mills are available in a wide range of designs, depending on the required geometry and application. The shape of the tool is achieved through grinding operations.
Micro-tools
In sectors such as the medical and dental industries, ever smaller tools are being used. These often include micro-drills and micro-milling cutters with diameters of less than one millimetre. Despite their small size, these tools are also often made from cemented carbide due to the combination of hardness, precision and wear resistance. Furthermore, internal cooling channels can be incorporated into micro-tools.
Which carbide grade is suitable?
Not every application requires the same type of cemented carbide. Properties such as hardness, wear resistance and toughness are determined, amongst other things, by the grain size of the tungsten carbide and the percentage of cobalt in the material. GSE10 is the grade of choice for many applications. This grade combines good wear resistance with broad versatility and is therefore widely used in the toolmaking industry. In addition, specific grades are available for applications where, for example, extra wear resistance, a finer grain structure or better compatibility with certain coatings is required. Which grade is most suitable depends on the application and the material to be machined.
From rod to tool
The production process for a tool usually begins with the selection of the right carbide rod. Depending on the application, the diameter, length, tolerance and type of carbide are selected. The rod is then pre-machined. This involves, for example, grinding diameters, steps or other shapes to the required dimensions. GSE Carbide can carry out these pre-machining operations based on a technical drawing. The tool manufacturer then applies the final tool geometry. This creates the cutting edges that determine the tool’s performance. For some applications, the tool is finished with a coating. This step is carried out either by the tool manufacturer itself or by a specialist coating partner.
Why choose GSE Carbide?
Tool manufacturers do not simply choose a supplier of carbide, but also a partner who works with them to consider material selection, manufacturability and potential applications. GSE Carbide stands out for, amongst other things:
- extensive stock;
- personalised service;
- tailor-made solutions;
- support with pre-machining;
- expertise in carbide grades and applications.
As a result, customers can count on a solution that is tailored to their specific production process and requirements.
FAQs from the toolmaking industry
Which type of carbide offers the longest tool life?
How are carbide rods manufactured?
Cemented carbide is produced from a mixture of tungsten carbide and a binder, usually cobalt. After the material has been shaped, it is sintered in special furnaces. Further machining operations, such as cutting or grinding, may take place.
When should you choose a tool with a coolant hole?
Coolant holes are used when heat dissipation and chip removal are important. By delivering coolant close to the cutting edge, higher performance and longer tool life can be achieved. The coolant holes in the tool also help to cool the material being machined.
What determines the price of a carbide tool?
The price of cemented carbide is influenced, amongst other things, by the type of cemented carbide chosen, the dimensions and the specification of the required rod or semi-finished product. Coolant holes and any pre-machining operations may also affect the price. The specification required depends on the tool that will ultimately be made from the material.