Cemented Carbide Powder Injection Molded Parts

Qinhuangdao Zhongwei Precision Machinery Co., Ltd. is a collection of copper alloy metal injection molding, iron-based metal injection molding, stainless steel-based metal injection molding, aluminum alloy metal injection molding, nickel alloy metal injection molding, cobalt alloy metal injection molding, tungsten alloy metal injection molding.A comprehensive high-tech enterprise integrating R&D, production and sales of injection molding, Cemented carbide powder injection molded parts and powder metallurgy structural parts.

Product Description

1. Implementation standards: the company strictly implements ISO9001, ISO14001, IATF16949 certification

The products have passed the certification of ROHS, FDA EU, etc.

2. Product material standards: ISO, GB, ASTM, SAE, EN, DIN, BS, AMS, JIS, ASME, DMS, TOCT, GB

3. Main processes: metal injection molding MIM, powder metallurgy PM, investment casting, die-casting aluminum,

4. Available materials for powder metallurgy:

Copper alloys, iron bases, titanium alloys, stainless steel bases, aluminum alloys, nickel alloys, cobalt alloys, tungsten alloys, cemented carbides, hydroxy alloys, soft magnetic materials and 3D printing can be customized according to customer requirements.

Experimental Results

Powder injection molding technology is a new type of powder metallurgy near-net forming technology. Compared with the traditional CNC blade manufacturing process, it has the characteristics of high precision, uniform structure, excellent performance and low production cost. It is known as "the forming technology of the 21st century". "

Figure 1-1 CNC turning, milling, threading, grooving inserts

1. Compared with the traditional blade, the hardened CNC blade based on the metal powder injection molding process studied in this project has the following characteristics:

(1) Carbide CNC inserts based on metal powder injection molding process have better wear resistance.

The tool moves automatically according to the CNC program. If the tool is not wear-resistant, it needs to be replaced continuously, and the efficiency of CNC machining cannot be exerted. For products with high precision machining and large program volume, the CNC tool needs to have better wear resistance. sex. In order to ensure dimensional accuracy and processing efficiency.

(2) Carbide CNC inserts based on all-metal powder injection molding process have better heat resistance.

During CNC machining, the tool generally performs continuous cutting, and the cutting heat is also continuously generated. Unlike ordinary equipment, the tool leaves the workpiece with a gap, so that the cutting heat has time to release. Although the cooling device of CNC machine tools is generally better than that of ordinary machine tools, due to the long time and high temperature of heat generation, it needs better heat resistance than ordinary tools to ensure the sharpness of the tools.

(3) Carbide CNC inserts based on Jinqu powder injection molding process have better impact resistance.

Good impact resistance is a quality that CNC tools must have in the process of interrupted cutting. When intermittent cutting is performed on ordinary equipment, the operator can adjust the feed speed at any time by manual operation for cutting, while CNC machining is performed according to the program. The feed rate is generally constant during the tool pass. If the feed rate is unreasonable, the tool is prone to jumping edges or even breaking.

(4) The hard and full CNC inserts based on the powder injection molding process have higher hardness.

The hardness of CNC tools is higher than that of ordinary tools. High speed is a major feature of CNC machine tools. During the cutting process, the speed is high, which can be used for grinding of high-hard materials. The hardness of the hard composite CNC insert based on the metal powder injection molding process is more than 109% higher than that of the traditional CNC tool

(5) Carbide CNC inserts based on metal powder injection molding process have better dynamic balance.

In the process of high-speed cutting, if the dynamic balance of the tool is poor, the tool will generate a large centrifugal force, which will greatly reduce the service life of the tool, and in severe cases, the tool will break, endangering the safety of equipment and operators.

(6) Carbide CNC inserts based on the metal powder injection molding process have higher manufacturing degrees.

CNC machining relies entirely on the machine tool to move the tool according to the program. Only the high precision of the tool can ensure the consistency of the size of the processed parts. Based on the powder injection molding process, the dimensional accuracy of the hard-core CNC inserts can be controlled within 0.4%.

(7) Carbide CNC inserts based on metal powder injection molding process have higher processing efficiency.

CNC machining products require good stability and high precision, automatic processing according to CNC programs, automatic tool change, continuous operation, and high quality stability of CNC blades. For products with high dimensional accuracy and high quality stability, high-precision CNC tools must be selected. In addition, it is also a major feature of CNC machining that the comprehensive performance of the tool is required to be good. Carbide CNC inserts based on the Cemented carbide powder injection molded parts process have higher comprehensive performance and thus achieve higher processing efficiency.

2. Technical innovation points of this project

(1) Select the appropriate binder to increase the powder loading; optimize the injection and degreasing process, reduce or avoid the formation of defects and shorten the deboning time; from the aspects of controlling the carbon content of the product, improving the performance of the product, and obtaining the ideal structure, etc. Conduct systematic research. A set of injection molding process suitable for ultra-fine carbide CNC inserts was explored.

(2) The effects of liquid-solid ratio, ball-to-material ratio, ball-milling speed and ball-milling time on the performance of ball-milling powder were studied. Gradually optimize to determine the best process parameters, prepare ultra-fine cemented carbide composite powder with uniform distribution and good powder dispersion, and realize the manufacture of cemented carbide CNC inserts based on Jinwu powder injection molding process.

3. Comparative analysis of this project with other similar products

The comparison and analysis of the four categories of CNC insert products developed in this project, including turning, milling, threading, and grooving, and foreign similar products are as follows.

(1) Product dimensional accuracy: The product dimensional accuracy of this project is controlled within 0.4%, reaching the level of dimensional accuracy of similar products of Sandvik (0.4%-0.6%);

(2) Product performance: The mechanical performance is 10% higher than that of the ordinary compression molding process, reaching the level of similar products in Japan and South Korea, and close to the level of similar products from Sandvik, Kennametal and Iscar;

(3) Production efficiency: It is 20% higher than the ordinary compression molding process, and the production efficiency is the same as that of foreign precision pressing;

(4) Production cost: It is 159%-25% lower than the ordinary compression molding process, and about 10% lower than the foreign precision compression molding process.

Post Casting Process

1. Heat treatment: annealing, carbonization, tempering, quenching, normalizing, surface tempering

2. Processing equipment: CNC, WEDM, lathe, milling machine, drilling machine, grinder, etc.;

3. Surface treatment: powder spraying, chrome plating, painting, sandblasting, nickel plating, galvanizing, blackening, polishing, bluing, etc.

Moulds and Inspection Fixtures

1. Mold service life: usually semi-permanent. (except for lost foam)

2. Mold delivery time: 10-25 days, (according to product structure and product size).

3. Tooling and mold maintenance: Zhongwei is responsible for precision parts.

Quality Control

1. Quality control: the defective rate is less than 0.1%.

2. Samples and trial run will be 100% inspected during production and before shipment, sample inspection for mass production according to ISDO standards or customer requirements

3. Testing equipment: flaw detection, spectrum analyzer, golden image analyzer, three-coordinate measuring machine, hardness testing equipment, tensile testing machine.

Application

The company's main product categories mainly include carbide cutting tools and blades, precision parts, compound and powder products and other molds and finished tools, etc., downstream matching automotive manufacturing, CNC machine tools, aerospace, military, mold processing, IT, Offshore engineering equipment and other manufacturing and processing fields.