Our cemented carbide machining technology
Example of small hole machining diameter 0.15mm, and polishing of inner diamater surface Ra0.04
Machining details
Small hole EDM machining
WEDM machining
Polishing
Machining shape
φ0.15×5㎜
Inner diameter surface roughness Ra0.04
Processing equipment
Small-hole Drilling EDM (Sodick K3BL)
Wire EDM Machine (Sodick AP450L)
Fluid polishing machine (Extrude HoneEX800)
Machined carbide grade
G2
*We are capable of this processing for all materials except stainless steel.
Customer's request
This is an example of small hole to be machined. The details of request are as below:
- To process a hole with diameter 0.15 x 5 mm, with inner diameter surface roughness of Ra0.05 or less.
-Select a low-cost cemented carbide material with high wear resistance and adhesion resistance.
In addition to the high degree of difficulty in processing, processing know-how was essential for processing cemented carbide.
As only a few vendors could handle it, the customer has contacted us.
Machining details
Based on the mechanical properties and product specifications required by the customer we proposed G2 grade, a highly versatile cemented carbide grade that meets the required wear resistance and adhesion resistance, and moved on to machining.
The details of the machining are small hole EDM and WEDM machining and polishing, but given the required specifications are severe it was necessary to pay attention to the following points:
-During small hole EDM machining, the electrodes were prone to wavering so it was necessary to set the optimal voltage, speed, and rotations.
-To obtain the target surface roughness after polishing, surface roughness after WEDM is essential and hence conditions that achieve both accuracy and surface roughness are required.
-It was necessary to achieve an inner diameter surface roughness Ra of 0.05 or less, but it is difficult to maintain roundness with conventional inner diameter polishing.
Regarding the optimum conditions for small hole EDM and WEDM machining, we figured out the optimum conditions by revising settings and prototyping based on the machining data of grade G2 and similar grades and shapes accumulated in the past.
Furthermore, we aimed to improve roundness and surface roughness by polishing the inner diameter using a fluid polishing machine instead of the conventional inner diameter polishing method.
With the above actions, we were able to achieve a hole diameter of diameter 0.148 to 0.151 mmm, an inner diameter surface roughness of Ra0.03 to 0.04 mm, and a roundness of 0.001 mm, which met customer's required specifications.
We then moved to production and delivered the parts after inspecting the hole diameter, roundness, and inner surface roughness (condition confirmation by magnified observation) using a video measuring microscope and contour shape measuring instrument.
Results of machining and service
In this case, the customer experienced problem finding a supplier who can handle this project.
Hence, we have been highly evaluated as we have carried out the small hole processing with diameter 0.15 x 5 mm with inner diameter surface roughness of Ra0.04 which was according to their specification, and we are providing continued service to them ever since.
Cemented Carbide Material/Carbide Machining Solution Navigator has strengths in fine machining and fine hole machining of cemented carbide.
For microfabrication of cemented carbide, it is necessary to repeat prototype processing based on the processing data in the past to determine the optimum conditions, and processing know-how is indispensable.
We will meet your needs by microfabrication considering the characteristics of the materials.
If you have any concerns about the microfabrication of cemented carbide, please feel free to contact us.
Our cemented carbide machining example
-
Catalog
We will provide high value-added cemented carbide with the achievements and know-how cultivated so far.
Download -
Consultation and Inquiry
We solve your problems by providing integrated solutions from material selection/development to precision machining and provision of finished products.
Contact us -
FAQ
We have posted the contents of many inquiries from customers in the past.
Click for details