For as long as there’s been tungsten carbide (which is roughly nine decades), machinists have been brazing small hunks of it to steel shanks and then grinding a sharp edge on the result. These brazed carbide tool bits and boring bars are easy to make, customizable to the application, and inexpensive. Unfortunately, their effectiveness depends on the machinist’s brazing and grinding skills. And since the tool must be removed from the mill or lathe for sharpening, they also lead to significant and costly machine downtime.
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HSS tool bits present a similar story. They’ve been around even longer than brazed carbide. They’re much less expensive than carbide and there’s no need for brazing—just sharpen the tip however you want and get cutting. Sadly, you won’t be cutting very long or very quickly because HSS boasts a cutting speed of just one-fourth that of tungsten carbide, and even less compared to some of the newer, coated grades. HSS might be fine for hobbyists with loads of time on their hands, but carbide is the first choice for professional machine shops.
That statement extends to HSS rotary tool bits such as end mills, drills, and reamers, all of which are used daily throughout the manufacturing industry. That’s a shame. Yes, these tools are less expensive than their solid carbide alternatives, but as mentioned, they’re also far less wear-resistant, predictable, and productive. These factors explain why leading cutting tool manufacturers emphasize the importance of carbide tooling to their customers and why many have stopped offering HSS cutting tools altogether.
That leads us to indexable carbide inserts, the workhorses of the machining industry. As with old-fashioned brazed tools, indexables also utilize small bits of carbide. The difference is how they’re attached. Rather than a permanent braze, indexable tooling relies on a screw or clamp to secure the carbide insert to the tool body. When the edge becomes worn, swapping it out only takes seconds. More importantly, there’s no loss of position or need to “touch off” the tool. Just remove the old insert, stick in a fresh one, and get to work.
Where machinists and toolmakers once had to grind special shapes into their brazed or solid carbide tools, they now have the option of buying off-the-shelf indexable inserts in a huge variety of geometries and styles. Need to cut a 1/16” wide groove in a shaft? How about an Acme thread, or a 45-degree chamfer around a part periphery? These and other insert shapes are readily available, no grinding necessary.
Indexable cutting tools are especially important on CNC machinery, where the need to keep spindles turning at all times is critical. Here, machinists rely on indexable drills—often with coolant running through them—to make holes quickly, followed by indexable boring bars to finish machine them. Indexable face mills true up large flat surfaces; indexable end mills rough out pockets and cut slots; indexable profiling tools trace complex part shapes. There’s very little that can’t be machined with indexable cutting tools.
But how do you know what carbide inserts and cutter bodies to buy? And why are there so many different grades of carbide inserts out there? Good questions; we’ll start with the second one first. Unlike a few decades ago, when machinists had just a few grades to choose from, there are now dozens of inserts grades, coatings, and chip-breakers available.
Many of these are tailor-made for specific materials or material groups. For instance, a shop making aerospace components can greatly increase efficiency by purchasing carbide inserts designed for tough, heat-resistant superalloys (HRSA) such as Inconel and Hastelloy. The same is true for medical shops, which tend to cut corrosion-resistant, biocompatible materials like 316 stainless steel, cobalt chrome alloy, and titanium. Automakers can dial in their processes by using inserts optimized for cast iron and low carbon steel, while oil and gas producers benefit from tooling that excels in duplex steel.
Simply put, if there’s an alloy out there, the chances are excellent that a material-specific carbide grade is available to cut it. However, some shops machine aluminum one day, iron the next, and titanium the day after that, often in low quantities. Does this mean they need to bloat their tool crib with dozens upon dozens of different carbide insert grades and geometries, many of which will only be used occasionally?
Probably not. Just as there’s no shortage of indexable carbide tooling optimized for certain materials, there’s also no shortage of excellent general-purpose cutting tools. These represent a middle ground between performance and the tool crib bloat just mentioned. That said, the decision to go the material-specific route is a delicate balancing act—if a job’s going to be in the machine for more than a few days or is sure to come around again in a month or two, it almost always makes sense to buy carbide inserts designed for that material.
Last but not least is the whole topic of insert nomenclature. It’s a deep subject, one filled with exceptions and cutting tool-specific rules. Regardless, most manufacturers follow the ANSI or ISO tool identification system (and sometimes both). We won’t get into the details here except to say that it uses an alphanumeric code to specifies an insert’s shape (round, square, triangular, etc.), clearance angle (neutral to positive), tolerance (some inserts are pressed to size, while others are ground), the size of the locating hole (if any) and clamping method, its size and thickness, corner radii, and various other defining features (see the chart above for an example).
Complex naming systems aside, however, choosing the right insert for your machining application isn’t as difficult as it might appear. That’s because cutting tool manufacturers have developed online tool advisors that walk machinists and programmers through the tool selection process. For example, Kennametal.com has a collaborative space that prompts users to answer questions about the metal removal process (milling, turning, or holemaking), the machine tool that will be used, workpiece material and removal amount, and expected depths of cut. It then generates a machining strategy along with insert and toolholder suggestions, ordering information, product availability, feed and speed recommendations, and more.
Long story short, carbide insert selection is much easier than it once was, even though the number of cutting tool options has grown exponentially since the days of brazed carbide and HSS tool bits. Download a catalog, log in to Kennametal.com or give your local cutting tool representative a call. You’ll be making chips in no time.
U drill, one of the most commonly used tools for hole processing, is usually called by different names, such as shallow hole drill, water jet drill, violent drill, fast drill, T-drill, insert drill, etc. The standard name should be indexable insert drill or machine chuck drill. The term “U-drill” originates from the Sandvik Coromant T-MAX U-drill, which was then widely circulated in the industry and gradually evolved into a common name.
There are several common types of SPMG, SOMT, WCMT, WCMX, the specific data can refer to the following table.
Types WC, SP and SO are the most commonly used U drill inserts in metalworking. Drilling operations are well suited for the use of indexable insert drills because they reduce the time required for tool changes. The technique of using u drills as roughing is very successful. Deeper cavities or holes can be created by making multiple axial cuts with a drill or milling cutter. This method is particularly suitable for roughing. Since the main cutting forces are concentrated axially along the spindle, it is energy-efficient, effective and reduces the requirements on the machine spindle. Drilling holes for the insert drilling tool is the first step in the internal insert milling process. The unique chipbreaker has a one-of-a-kind design incorporating corrugated edges. This ensures both high edge strength and effective chipbreaking.
The U drill, also known as a drill with indexable inserts, is a tool primarily used for high-efficiency hole drilling in various materials. Below is a detailed explanation of how a U drill works:
U drill inserts are cutting tools used in indexable U drills, specifically designed for high-efficiency hole drilling. These inserts are typically made from carbide or other hard materials, which are capable of withstanding high cutting speeds and temperatures. They are replaceable, meaning once an insert becomes dull, you can swap it out instead of replacing the entire drill, making them cost-effective.
High Efficiency: U drills with inserts can drill holes much faster than traditional twist drills because they cut using two inserts simultaneously—one for the hole center and one for the perimeter. This reduces machining time significantly.
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Cost-Effective: Since the inserts are replaceable, the overall tooling cost is reduced. Instead of replacing an entire drill, you only need to replace the worn inserts.
Versatility: U drill inserts can be used on various materials such as steel, stainless steel, cast iron, and non-ferrous materials. Different insert geometries and coatings are available to suit different applications.
Precision: U drill inserts provide high precision when drilling, often creating holes with minimal need for secondary finishing operations like boring or reaming.
Coolant Delivery: Many U drills are designed with internal coolant channels that cool the inserts during drilling, improving tool life and chip evacuation.
To ensure optimal performance when using U drill inserts, several factors need to be taken into account:
Choose the correct insert material (carbide, coated carbide, etc.) based on the workpiece material. Different materials require specific inserts to achieve the best results. For instance, tougher inserts may be needed for drilling through hard steels, while softer materials like aluminum may require a more specialized insert geometry.
The cutting speed and feed rate should be appropriate for the workpiece material and insert type. Excessive feed rates can cause insert failure, while too low feed rates may result in poor chip formation or excessive heat buildup.
Consult the manufacturer’s guidelines for recommended speeds and feeds, adjusting based on material hardness and depth of hole.
Ensure that coolant is properly directed to the cutting zone. Coolant helps to reduce heat, prevent tool wear, and aid in chip evacuation. U drills often come with internal coolant channels, but you must ensure these channels are functioning correctly.
Using insufficient coolant or having a blocked coolant passage can lead to overheating, reduced tool life, and poor hole quality.
Make sure the inserts are properly seated and secured in the U drill body. Improper installation can lead to insert shifting, poor hole quality, or even damage to the tool body.
Periodically check for insert wear and replace inserts when they are dull to avoid damaging the workpiece or tool.
Monitor chip evacuation during the drilling process. Poor chip removal can cause chips to clog the hole, leading to tool failure, overheating, or workpiece damage.
Adjust feed rates or coolant flow if chips are not being effectively removed from the hole.
U drills are ideal for producing holes quickly, but accuracy can vary depending on the setup and material. For deep holes, ensure proper alignment of the U drill to avoid deviation, which can lead to tapered or out-of-round holes.
Keep track of insert wear during use. Worn inserts can negatively affect hole quality and may also cause excess heat, increasing the risk of breakage or damage to the workpiece.
Regular inspections and timely insert changes are essential to maintain hole quality and extend tool life.
By following these guidelines and using the right insert for the application, you can maximize the efficiency, cost-effectiveness, and precision of U drills in your machining operation
The U-drill is a drilling tool containing carbide inserts characterized by ease of use and cost-effectiveness. In order to facilitate the machining of a wide range of materials, ONMY U-drill inserts are available in a variety of types and sizes.ONMY U-drill inserts offer an energy-saving and efficient solution, in addition to a high metal removal rate. For high quality U-drill inserts, contact ONMY! Contact us and we will be happy to answer any questions or concerns you may have.
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