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Indexable Carbide Inserts

What is Indexable Carbide Inserts

Indexable carbide inserts are replaceable cutting tips used in turning, drilling, milling, and other metalworking operations. These inserts are made of ultra-hard tungsten carbide and are designed to be removed and replaced when worn or damaged, rather than having to replace the entire tool. They are popular because they offer excellent wear resistance, cutting performance, and accuracy, and can be re-sharpened and reused multiple times. The geometry and size of carbide inserts are carefully engineered to provide precise cuts and long tool life, making them an essential tool in modern manufacturing.

Advantages of Indexable Carbide Inserts

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Cost-effectiveness: Indexable carbide inserts are cost-effective in the long run as they can be changed and rotated easily without the need to discard the entire tool. This means reduced tooling cost and improved machine productivity.

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Time-saving: As carbide inserts can be indexed quickly and easily, it saves time and increases production efficiency.

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Durability: Carbide inserts are extremely durable and can withstand high temperatures and cutting forces without breaking. This makes them ideal for high-speed machining operations.

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Versatility: Carbide inserts can be used for a variety of cutting applications, including turning, milling, boring, and drilling. This makes them a versatile tooling option for different types of industries.

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Accuracy: Carbide inserts provide precise cutting, which helps to achieve tight tolerances and better surface finishes.

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Easy to use: Carbide inserts are easy to install and replace, even for those who are new to cutting and machining operations.

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Common Types of Indexable Carbide Inserts

Turning Inserts

These are the most common type of indexable carbide inserts used for turning operations. They are used for machining on the outer surface of a workpiece.

Milling Inserts

Milling inserts are used for milling operations to remove material from the surface of a workpiece. They come in different shapes and sizes to suit various cutting applications.

Drilling Inserts

Drilling inserts are used for drilling holes in materials. They come in various shapes and sizes to suit different drilling applications.

Grooving Inserts

Grooving inserts are used for creating grooves on the surface of a workpiece. They come in different thicknesses and widths depending on the groove diameter required.

Threading Inserts

Threading inserts are used for creating screw threads on the surface of a workpiece. They come in different thread profiles to suit various threading applications.

Parting Inserts

Parting inserts are used for cutting off a workpiece in a machining operation. They come in different widths to suit different parting applications.

Indexable Carbide InsertsBenefits Over Solid Tools

Indexable Carbide Inserts tools have been in use since the late 1920s and are now ubiquitous in the metalcutting world. Around 1950, tools that accept cemented-carbide inserts became common in metalworking and are still considered a basic necessity.

Indexable cutters are typically constructed of a steel body that has machined features, allowing for the accurate positioning of inserts. Steel tool bodies also provide a method for clamping inserts along with a method for attaching the assembled body and inserts into the machine tool.

Before the proliferation of carbide inserts, it was always necessary to remove solid cutting tools from machines to sharpen them. Tool sharpening was such a significant amount of work that large manufacturers often had grinding departments dedicated to tool sharpening. Therefore, the single most significant benefit offered by indexable tools is the ability to renew the cutting edge without having to remove the cutting tool from production. Renewal of the cutting edge is typically done by unclamping the insert and turning or flipping it (indexing) to a fresh cutting edge or replacing a completely worn insert with a new one.
This facemill accepts inserts with 16 cutting edges, making the inserts cost-effective. Image courtesy C. Tate.

Solid drills, taps and other types of cutting tools are still used, depending on the application, but the indexable turning tool is the predominant tool of modern turning operations. Indexable tools have effectively displaced HSS, brazed-carbide and custom form tools, which were common prior to the proliferation of CNC machines. An indexable turning tool paired with the multiple-axis motion of a CNC machine tool simplifies the creation of complex shapes, virtually eliminating the need for dedicated turning tools.

In addition, applying indexable drills on a lathe provides some distinct advantages over traditional solid HSS or carbide twist drills. It is common for a programmer to make a hole with an indexable drill and then step off center and cut the hole to a larger diameter, which can eliminate the need for a boring bar. CNC lathe turrets frequently suffer from misalignment because of wear and tear, and misalignment of the machine can damage standard drills. On the other hand, indexable drills are more forgiving than standard drills when used on machines with questionable alignment.

Groove-turn inserts, which have made grooving tools multifunctional, like indexable drills, present a significant development in turning tools. Old grooving technology allowed cutting in only one direction; groove-turn inserts allow the user to make radial as well as axial cuts.

The Common Touch

There is a tremendous amount of commonality among indexable turning tools. Turning inserts are manufactured in common shapes, such as diamond, square and round. The shapes and sizes of these inserts are made to standards governed by bodies such as ANSI and ISO. Their commonality gives the programmer and machinist an almost unlimited selection of insert grades and cutting-edge geometries. All of the major cutting tool manufacturers produce turning inserts to these standards, so finding an insert that gives the best performance is relatively easy.

Unlike turning tools, indexable milling tool bodies tend to require insert shapes and geometries that are not common among manufacturers, forcing users to purchase inserts made specifically for the brand of mill they use. However, toolmakers have been developing and offering families of milling tools that utilize their proprietary shapes across a range of cutter bodies. Having a family of cutter bodies that accept the same insert reduces tool inventory while providing some flexibility to programmers and machinists.

Most of the major toolmakers manufacture custom indexable form tools. Unlike form tools for turning, form tools for milling are still a viable way to complete a complex geometry, especially when a shop is trying to reduce cycle time and cutting tool inventory. Parts with features such as multiple steps, radii and chamfers require the use of multiple tools to create them. The advantages of custom, combination indexable form tools are reduced cycle times, reduced tool inventory and improved part quality.

This boring bar for a lathe allows different cutting heads to be bolted on, so multiple styles of inserts can be applied. Image courtesy C. Tate.

Unfortunately, custom indexables are expensive and often require modified inserts, making the inserts expensive as well. For these reasons, custom indexable tools are usually reserved for high-production environments or for manufacturing very expensive parts.

How Indexable Tools Keep Their Edge

Sales figures don't lie: indexable cutting tools-featuring removable cutting tips called inserts-are a smash hit with machine shops. Though not right for every cutting application, indexable tools have a number of inherent advantages over solid tools that account for their competitive edge in the tool market. In recent years, moreover, the competitive position of indexable tools has been strengthened by advancements that have increased tool life, improved cutting performance and sped up changeout.

What accounts for the popularity of indexable tools? Fundamentally, they are efficient tools for metal removal because of their structure, which typically consists of a number of carbide inserts installed in a steel body.

While a solid-carbide tool is very hard and resists abrasive wear, "it is also on the brittle side so you are limited as to how hard you can push it," Pollock said. With indexable tools, however, the toughness of the steel body comes into play. "You usually don't think about an indexable milling body breaking, but solid-carbide tools break all the time," he noted, adding that the steel body also makes indexable tools less susceptible to vibrations.

The steel body of an indexable tool is used over and over while only the cutting edge is replaced. Normally, carbide inserts will have more than one cutting edge. When worn, the cutting edge is changed by turning or flipping the insert - i.e., indexing - to an unused cutting edge. According to Pollock, some tool designers focus on creating as many cutting edges as possible on one insert to improve the cost benefit of using their tools.

Due to the relatively high cost of carbide compared to steel, solid-carbide tools tend to be smaller than indexable tools. While the diameter of a common solid-carbide end mill might be ½" (12.7 mm) or ¾" (19 mm), Pollock said, indexable tools normally start at ¾" (19 mm), with 2" (50.8 mm) and 3" (76.2 mm) diameter sizes more common.

Much larger sizes are also possible. "You couldn't create a 10" (254-mm) diameter cutter out of solid carbide because it wouldn't be economically feasible," Pollock said. "But with a steel body, it is very easy and cost-effective to do."

This is due to the price of steel and the relative ease of machining insert pockets into a steel body. "If you had a 10" (254-mm) diameter tool, you could easily put 10, 15 or even 18 carbide cutting edges in the steel body" .

At Greenleaf Corp., Saegertown, Pa., tool designers found that adding more pockets to their face-milling tools actually adds to the life of the inserts in the tools. What makes the difference is the extra inserts in those additional pockets. More inserts stabilize the cut and reduce the forces on each insert, which in turn reduces the number of times the inserts must be indexed, explained Martin Dillaman, Greenleaf's applications engineering manager. "You may be adding some cost by adding an insert or two to the tool, but the productivity increases outweigh that," he said.

Dillaman added, however, that tool designers must be careful not to add so many insert pockets that there is no longer enough steel in the cutter to maintain adequate strength. In addition, users of tools with large numbers of inserts must make sure that their machines are up to the task of using all the cutters.

"When you have multiple teeth in the cut, the forces required to spin the cutter go up significantly," he said. "So you may run into instances where you will essentially stall the machine."

A Small Problem for Indexables
While indexable tools are the most popular choice for roughing, the situation is different for cutting applications that require smaller tool diameters or greater precision. In holemaking, for example, indexable tools have a much lower share of the U.S. cutting tool market, accounting for just 30 percent in 2017, according to McKinsey & Co., while solid-carbide tools accounted for 40 percent and solid non-carbide accounted for the remaining 30 percent.

Selecting The Correct Indexable Inserts - What Do I Need To Know?

Indexable inserts offer a significant advantage compared to other cutting tools: If a cutting edge of the indexable insert is worn, it is simply turned to an unused cutting edge – no need for regrinding. This ensures that ongoing production is only interrupted briefly and there is no need for a time-consuming setup of the tool.
Which cutting insert to use depends on the type of production and the material to be machined, and its level of hardness. There is a wide range of indexable inserts of different shapes and material, which makes selecting the correct indexable inserts tricky.

Indexable inserts to international standard

In order to prevent errors, indexable inserts are standardized internationally. This ISO standardization specifies the size, shape, mounting, material properties and coating. The cutting machine operator uses the ISO indexable insert designation to select the appropriate indexable insert needed for the relevant application.

The ISO code can include up to twelve characters. The first to seventh characters indicate mandatory information. The eighth and ninth provide optional information which is used as required. The tenth to twelfth are optional manufacturer details and are added separately to the ISO code using a hyphen.

The seven mandatory fields indicate the insert shape or the clearance angle and other core features of the cutting insert. The characters have individual identification letters and numbers which clearly identify an indexable insert. In order to be able to assign the appropriate dimension to these identification letters, tables conforming to DIN4983 are available which can be looked up in a table book.

Manufacturer-specific details are indicated after a hyphen and, depending on the company, specify the chamfer width, chamfer angle, cutting material or shape of the chip breaker. The relevant legend is taken from the manufacture catalogues.

The ISO code comprises 9 symbols, of which symbols 8 and/or 9 are only used as required. The manufacturer can add other symbols, which are added to the ISO code by a hyphen (e.g. for the shape of the chip breaker).

Tips for selecting the correct indexable insert

To achieve good chip control and the best machining results, the geometry, grade, shape (point angle), size, corner radius and setting angle of the indexable insert should be selected carefully.

Select the indexable insert geometry based on the selected application
For roughing, we recommend a combination of large cutting depth and high feed rate. Roughing applications place high demands on the cutting edge dependability. Finishing is an application which requires low cutting forces as shallow cutting depths and low feeds are generally needed.

Select the largest possible point angle
A large point angle is stable, requires increased machine output, but can also tolerate higher feed rates. High cutting forces are therefore possible, but the tendency for vibrations also increases. With a small point angle, the cutting edge is less stable and it has a small cutting edge engagement; thereby increasing the thermal sensitivity. The insert has a smaller cutting force.

Indexable Carbide Inserts - Selecting the Correct Setting Angle

The setting angle KAPR is the angle between the cutting edge and feed direction. It influences the chip formation, direction of the cutting forces and the cutting edge length being engaged. With a large setting angle, the forces are directed towards the chuck, thereby producing a reduced tendency to generate vibrations. It allows shoulders to be turned and produces higher cutting forces during entry and exit. However, with the large setting angle there is a tendency towards notch wear in HRSA and case-hardened materials. The smaller setting angle increases the tendency for vibrations to be generated as higher radial forces are directed into the component. But on the other hand, the cutting edge is under less strain and a thinner chip is created, which allows for increased feed rates, and the notch wear is lower. However, it is not possible to turn against a 90-degree shoulder.

Selecting the correct cutting material and coating

The material of the cutting insert should essentially be hard and resistant to deformation, whilst at the same time also tough, in other words, not brittle, should not react to the material and should be overall chemically stable, i.e. resistant to sudden thermal alternating stress, oxidation and diffusion. Cutting inserts are available made of carbide, ceramic, boron nitride and diamond. Indexable insert geometry and grade complement each other: the degree of toughness of one grade can compensate for the lack of stability of an indexable insert geometry.

Carbide: Temperature resistant up to 1000 degrees, high wear resistance and high pressure resistance.

Ceramic: Temperature resistant up to 1200 degrees, great hardness, high degree of toughness and suitable for increased cutting speeds.

Boron nitride: Temperature resistant up to 2000 degrees, high wear resistance, great hardness.

Diamond: Extremely high wear resistance.

To improve the properties, indexable inserts are often coated with hard materials such as titanium carbide or titanium nitride in order to further improve the wear resistance and heat resistance.

Typical applications of uncoated carbide grades include the machining of heat-resistant super alloys (HRSA) or titanium alloys and the turning of hardened materials at lower speed. The result is increased wear compared to coated grades.

CVD-coated grades are the first choice for a wide range of applications where wear resistance is the deciding factor. CVD stands for chemical vapour deposition. The CVD coating is applied through chemical reactions at temperatures of 700-1050 degrees. These applications are found with general turning operations and when drilling into steel, where the thick CVD coatings provide resistance to crater wear, and with general turning operations of stainless steels and milling grades in ISO P, ISO M and ISO K. When drilling, the CVD grades are usually used in the outer cutting edge.
PVD-coated grades, i.e. with coatings produced by means of physical vapour deposition (PVD), are also recommended for adhesive material due to their tough, yet sharp cutting edges. The application range is diverse and includes all solid carbide milling cutters and drills and most grades for grooving, thread cutting and milling. PVD-coated grades are also used on a large scale for finishing operations and as centre cutting grades when drilling.

Our Factory

Zhuzuan (Chongqing) CNC Tool Co., Ltd. is a professional enterprise engaged in the research and development, production, and sales of CNC cutting tools. We cooperate with ZCC.CT and establish a long- term cooperation friendship. Our company was established in 2017 and is located in Shuangfu Industrial Park, Jiangjin District, Chongqing city. The environment is elegant and the transportation is convenient. Our company has advanced production equipment and an experienced technical team, committed to providing customers with high-quality CNC tool products and high-quality after-sales service.

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FAQ

Q: What are indexable carbide inserts made of?

A: Indexable carbide inserts are made using a composite material that combines carbide particles and a binder metal. The most common binder metals used are cobalt and nickel. Carbide inserts are known for their high wear resistance, toughness, and ability to operate at high temperatures.

Q: Why should you use indexable carbide inserts?

A: Indexable carbide inserts offer several benefits, including high speed cutting, improved tool life, and excellent accuracy and surface finish. They are also highly versatile, allowing one tool holder to be used with multiple cutting inserts.

Q: How do indexable carbide inserts work?

A: Indexable carbide inserts work by clamping the insert onto a tool holder or chuck. Once in place, the insert can be rotated and positioned to create the desired cutting action. As the cutting edge becomes dull, the insert can be replaced with a new one, preserving the accuracy and precision of the machining process.

Q: What are some common types of indexable carbide inserts?

A: Some common types of indexable carbide inserts include turning inserts, milling inserts, drilling inserts, threading inserts, and grooving inserts. Each type of insert is designed to perform a specific machining operation, such as rough turning, finish turning, face milling, plunge milling, drilling or tapping.

Q: How do you select the right indexable carbide insert?

A: Selecting the right indexable carbide insert depends on several factors, including the material being machined, the machining operation being performed, the desired surface finish, and the machine's horsepower and speed capabilities. It's important to choose an insert with the right geometry, grade, and coating to achieve the desired results.

Q: How do you maintain indexable carbide inserts?

A: To maintain indexable carbide inserts, it's important to keep them clean and free from chips and debris. It's also important to use coolant and lubrication when machining to prevent overheating and premature tool wear. Finally, it's important to replace dull or worn inserts promptly to maintain accuracy and precision in the machining process.

Q: What are the advantages of indexable inserts?

A: Indexable inserts offer a significant advantage compared to other cutting tools: If a cutting edge of the indexable insert is worn, it is simply turned to an unused cutting edge – no need for regrinding.

Q: What makes a carbide insert indexable?

A: The steel body of an indexable tool is used over and over while only the cutting edge is replaced. Normally, carbide inserts will have more than one cutting edge. When worn, the cutting edge is changed by turning or flipping the insert—i.e., indexing—to an unused cutting edge.

Q: What are some advantages of carbide insert tools?

A: The Benefits of Carbide Tools:

Tools made of Carbide are cheap and effective in comparison to other types of HSS tooling options. They are durable at most and also can endure high-temperatures, turning at a very high-speed – this type of exposure wears other types of tooling metals down.

Q: What is the major advantage of using inserted indexable carbide cutting tool?

A: Answer. The main advantage of indexable mills is that they are cost-effective relative to the use of solid mills. When a solid mill becomes dulled, it must be replaced or re-sharpened. On the other hand, when an insert becomes dulled, it can be rotated several times before a replacement is needed.

Q: What is unique about indexable insert drills?

A: This extremely tough grade offers superior heat resistance, allowing it to be used in a wider application range to give you increased versatility and a greater output.

Q: What are indexable inserts?

A: Indexable inserts from Kennametal come in a range of shapes and geometries for several holemaking applications. Choose from specially designed high-precision inserts for better chip control while machining difficult materials to combination tool inserts that are perfect for chamfering and spot-facing in one operation.

Q: What is the difference between indexable end mill and face mill?

A: Design: An indexable end mill consists of a solid body with flutes or cutting edges on the side, while a face mill is a larger tool with a flat cutting surface, often in the shape of a disc or cylinder.

Q: What is the difference between indexable and modular drills?

A: Indexable drills are used for general purpose and small-hole drilling. Modular drills use exchangeable cutting tips for drilling.

Q: How do I choose a carbide insert?

A: Always select a carbide insert size based on the specific application needs and space for cutting tools in the application. Relatively large insert size provides better stability. Heavy machining requires a carbide insert size of above IC 25mm.

Q: How do Indexable tools keep their edge?

A: The cutting edges of indexable tools are typically made from hard and wear-resistant materials such as carbide, cermet, or cubic boron nitride (CBN). These materials can withstand high cutting temperatures and provide excellent wear resistance, ensuring the cutting edge retains its sharpness for longer periods.

Q: Which is better HSS or carbide inserts?

A: Carbide is much harder, so it has a longer tool life and faster cutting data than conventional HSS. The downside of that hardness is brittleness, so the cutting edge on carbide tools can quickly fracture or chip in certain situations.

Q: What is the purpose of a carbide insert?

A: The purpose of carbide inserts is to enable the workpiece to be machined efficiently. In this sense, it is of utmost importance to make sure that you choose the right tool for the purpose you have in mind. Several materials are available to us, including Aluminum, Bronze, Stainless steel, Cast Iron, and many others.

Q: Is a carbide tipped tool better than a high-speed steel tool?

A: Mostly under the same conditions, the cutting speed of tungsten carbide tools is 4 to 7 times higher than that of high-speed steel, and the life is 5 to 80 times higher.

Q: Which drilling tool produces the most accurate drilled holes?

A: Reamers can come in several configurations, including machine, left-hand spiral, right-hand spiral, and straight flute. These metal working tools have an incredibly high degree of accuracy, making them perfect for slightly enlarging existing holes.

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