Question regarding cutters 2

[olixus]

Hi all,

Without going to much into details, I am trying to find the best option in terms of material for a cutter that is used every second (1.125s to be exact) and that cuts through a steel wire (max 1/5" thick).

At the moment, we are using steel cutters that are changed every 4000 pieces because of deformation at the cut. It take between 10-20 minutes to change them. This can slow down production considerably.

Anyone have any suggestions in terms of material for a cutter that would prolonge its life and produce quality cuts (which is very important). My inexperience makes me think right away of diamond cutters, but I believe they can be brittle?

I appreciate any comment that could lead me on a track. Thank you

Olixus

 

[tomwalz]

Tungsten carbide?

A proven material in this application. Should give 30 to 50 times the life.

Diamond is usually PCD on a carbide backing. Great wear resistance - not so great on fracture resistance.

There are also super alloys. E.G. cobalt based alloys that will give 10, 20, 30 times the life of steel but still have the fracture toughness of a metal alloy.

If you wish to call we would be happy to help you.

Tom Walz
Carbide processors

Thomas J. Walz
Carbide Processors, Inc.

http://www.carbideprocessors.com

Good engineering starts with a Grainger Catalog.

 

[olixus]

Hi Tom, thanks for the reply,

Before proceeding, I think it would be good that I tell you that the steel we are currently using is M2 (high speed steel in tungsten-molybdenum series[sup]1[/sup])

The cutters are manufactured here and come to a total cost of 30$ a cutter. Considering we do mass production, it is very costly (we can change a cutter 6 times a day or more).

The cutting system is rather simple in the sense that as the steel wire reaches the desired length, the cutter comes in contact with. I do not have the speed, but it cuts a piece every 1.125 second and has max +-2 inches distance initially.

Do you think tungsten carbide would be suitable for this application or is the "shock" going to provoke early wear?

thanks,

Olixus


[sup]1[/sup]wikipedia.

 

[BillPSU]

I don't understand how your tool is cutting the part off but there are some very shock resistance grades of carbide to do just about anything. If you have concerns about what grade to use call a carbide sales rep and he can advise you.

Bill

 

[TVP]

olixus,

PCD is not going to be a good candidate for this application. You should investigate a shock/impact resistant grade of cemented carbide.

 

[tomwalz]

Rotating or reciprocal cutter?

We buy 0.047” diameter braze alloy wire and chop it to length (+ /- -.005”) so I am familiar with this sort of an application. We feed the wire though the hole in an anvil and sue a rotating chopper. We get a small hook due to the ductility of the wire but this is actually advantageous in further processing. Your wire is much harder than mine.

You say you build your own cutters. As a guess you might investigate the possibility of using a standard machining insert as the cutting edge.

As others have said; carbide can be very tough. I once took a carbide saw tip and fired it from a .410 shotgun against a concrete block wall. The wall was slightly chipped but the tip was fine. (If you do this then hide around the corner as I did. You don’t want to get hit with a ricochet.)

There is a huge industry devoted to quick change tools. If you have a machine shop you might ask those folks.

Have you heard the story of the empty toothpaste boxes? The way I heard it. A big toothpaste company is having a problem with the occasional toothpaste box that doesn’t get filled buy does get in the box and is shipped. They call in the engineers. The engineers measured and tested. They developed a scale that weighed every box and an arm that pulled the empty ones off . It took them a couple weeks. When they got the scale and arm up to the line they found that the problem had been solved using a fan to blow the light ones off.

This is especially funny here because this forum is full of “fan” type engineers.


Thomas J. Walz
Carbide Processors, Inc.

http://www.carbideprocessors.com

Good engineering starts with a Grainger Catalog.