Best Manufacturing Tips on Carbide Tools, Cutting Tools, Threading Tools & Boring Tools

1]Trepanning tools are used in manufacture of Gun Barrels, Pipes for oil well drilling, Large Motor and Alternator shafts and such parts.

2] They save time,electric power/energy and material as compared with solid drilling/ boring.

3] They leave a core which can be used for analysing and making other parts while drilling expensive materials.

4] Trepanning is the only process available to manufacturers where in large and long holes have to be drilled.

5] They can be used for drilling large holes in small length parts too.

1] External Threading Tools:

These tools are used to cut screw threads on the outside diameter of components/parts such as bolts, shafts, pipes, castings and forgings made from ferrous and non ferrous materials.

These tools can be used to cut screw threads in Metric, British, Acme and other standards.

2] Internal Threading Tools:

These tools are used to cut screw threads on the internal diameters of components/parts such as nuts, pipes, collars, castings and forgings made from ferrous and non ferrous materials.

These tools can cut screw threads in Metric, British, Acme and other standards.

The major diameter of the thread has to be machined prior to external threading and the root diameter of the thread has to be machined prior to internal threading.

It is very important to provide an undercut on the outside or inside diameters  before carrying out thread cutting as this allows the threading tool to pass into the undercut just after carrying out threading to the required length and before it returns to the starting point.

While cutting threads it is essential to use a cooling medium such as straight oils or oil in an emulsion with water.

Thread cutting is always done in multiple passes of depths of about 0.1 mm or 0.004 inch to reduce load on the lathe as both cutting edges are working together, maximise tool life and achieve proper thread form to meet gauging requirements.

Overhang of the threading tools is a major factor that contributes to vibration, poor cutting conditions and poor thread form.

As the pitch of threads vary from 0.5 mm to 5.0 mm the rotational speed on conventional lathes are kept low. However, higher speeds can be used in CNC Lathes as the tool return is preset on the machine and controlled.

Care should be taken while setting up for threading so that over run of the threading tool is avoided as it may cause major accidents and damage to the tools and the machine.

 

Carbide tipped tools are used widely in
1] Mining of Coal, Iron Ore and other ores in the form of Augurs, Cutter Picks, Coal Picks etc.
2] Weld bead removal of Electrical Resistance Welded steel tubes.
3] Aircraft component machining.
4] Cutting off knives in machines that mass produce fasteners, needle roller and other types of bearings.
5] Heavy duty planning machines and roll turning lathes for steel mills and heavy engineering industries.
6] Fine boring machines where the corner radii of the tools are very small.
7] Single spindle and multi spindle automatic lathes that mass produce components with profiled grooves and forms.
8] Chisels that are used in making rough, medium and smooth files.
9] Revolving Centers and Dead Centers.
10] Wood working tools and cutters.
11] Machining of steel, cast iron, aluminium and non ferrous components for all types of industries.

 

I have been in the manufacturing industry for the last 35 years and we started Tectools 25 years ago. A new client of mine in the United States sent me an email suggesting that the tools I just shipped to him looked very familiar to the tools he was purchasing for the past 20+ years. I really don't know if this was a coincidence or he may have got it from various distributors that I supplied to.

Back in 1980's and 1990's for every company to grow, the location was the prime factor. Every city's infrastructure was the primary driver for small businesses to grow. The better the infrastructure of every city, the more the people the city would attract, small business could thrive.

Today location is still a prime factor for a business to thrive but not the only factor. Companies like amazon.com took the advantage of the world wide web and successfully sell most products at the best rates. Our goal is to take our company virtually to the client (by Video's, Blogs and our Website) so that the client can have an understanding of who we are and what Tectools do. We are still at the incipient stages and are hopeful that we can accomplish this task successfully in the future.

It is disappointing see a lot of manufacturing companies who manufacture rigid tools, carbide tools, lathe tools, woodturning tools, carbide drill bits and trepan tools who try and take the easy path and make cold calls to a client and wait for weeks to get some kind of a response. What they don't realize is there is opportunity out there to get found using the web effectively.
If you are a large manufacturing company and a manufacturer of cutting tools & threading tools, lathe tools, carbide insert & carbide burrs the best way to attract clients is to engage the clients with technical blogs.
At Tectools we have been focusing on technical blogs for a while and our results have been very positive. Once a potential customer is interested in us we provide free samples to them for their approval and evaluation. It is very important for clients to view the quality of tools we provide. Throughout this interaction with the client we actually make the potential client feel valued. There are cases where I have had people contact me about how to manufacture some tools, I have offered my advice on ways to manufacture tools effectively. It's not just all about getting orders, but more about building a relationship with clients.

If you are a manufacture of carbide tools & threading tools, lathe tools, woodturning tool and trepan tools you must have a website for marketing purposes. After I have put up my website, followed I have noticed I have converted quite a few leads into customers.
I have received some questions from my colleagues about why one needs to create a website for a Medium Scale industry manufacturing Carbide Tools & Threading tools. They seem have a wrong impression that a website is only for display purposes and nothing to do with marketing.
Below are 6 questions I frequently ask colleagues just getting started to build their website for marketing purposes:
1. Are you a manufacturer or a distributor and who are your primary customers?

2. How big is your industry and what message is to be conveyed to your audience?

3. Do you know what information your customer is looking for and how you can try and convert a visitor to a lead?

4. Do you take some time to write some technical blogs about your business?

5. Do you try and add some videos about your company so that the visitor gets a virtual tour of your company?

6. Can you try and update your website by blogging at least once in a week/fortnight?

A website is just a marketing tool for you to get found by people. One needs to effectively utilize this tool to the maximum to run your business in today's world.

 

 

Raw materials Used:

1] Bright drawn steel rods of 20x12 mm to AISI 1018 specification.

2] Carbide tips as per ISO D 4 of P30 grade.

Procurement of Raw materials:

1] Procure steel rods from approved sources only along with material test certificates.

2] Procure carbide tips from the approved source in Europe or from Kennametal in India. TecTools Engineering a manufacturer of cutting tools & threading tools sources its carbide from Europe.

Inspection of Raw materials:

1] Carry out chemical analysis of the steel rods and check against specifications

2] Visually inspect the steel rods for defects such as cracks, deep dents and heavy scoring marks and clear materials if ok for all the above checks for manufacture.

3] Check the grade of the carbide tip to ascertain that the right grade is being used for manufacture of the tools.

Manufacturing Procedure.

1] Set and cut steel rods to lengths of 127+ 3 mm and check.      

2] Set and mill the front clearance to 0 deg x 8 deg and maintain overall length of 125+6mm and check.

3] Set and Mill the tip seating area at a positive rake angle of 0 deg x8 deg parallel to the front edge and maintain height over tip between 19.8 and 20 mm and check.

4] Set and mill the left side clearance angle of the grooving & recessing tools at 1 deg x 2 deg to maintain width of 11.8 mm at the front end of the shank and check.

5] Set and mill the right side clearance angle of 1 deg x 2 deg x 45 deg with a form cutter to maintain front width at 3.6 mm.

6] Mill a positive top rake angle of the cutting tools at 8 deg x 30 deg parallel to the tip seat to a width of 15 mm from the front end and check.

7] De burr the cutting tool shanks and stamp the designation as ISO 7 R 2012 P 30 or as DIN 4981 R 2012 P30 and check.

8] Carryout inspection of all operations done so far.

9] Grind the D 4 P30 carbide tips to remove the sintered surfaces on the brazing area.

10] Degrease the shanks of the recessing tools and the carbide tips and ensure that the brazing area is free of rust.

11] Procure Silver foil of 0.1 mm thickness having min of 49% silver content and devoid of any Tin or Lead from Degussa in Germany or from an approved source in India

12] Apply suitable brazing flux on the tip seat area, build up a sandwich of 2 silver foils and a copper foil in between with brazing flux in between them and place them on the tip seat area, apply brazing flux to the area of the tip that gets brazed, place the tip to be brazed on top of the sandwich of foils. Allow to dry.

13] Set the Induction brazing machine with a suitable induction coil and power tapping points.

14] Insert the cutting tool to be brazed with the carbide tip into the induction coil and start heating. Stabilise heating when the steel shank turns from blue to mild red in colour. Start heating again to take the carbide tip and the steel area surrounding it to the melting point of silver. Press the tip into position with a pointer rod and allow the cutting tool to cool to about 200 deg C. Remove the tool from inside the induction coil and place it in pre heated sand and allow it to cool to the room temperature.

15] Inspect the joint to ensure that the carbide tip is brazed properly onto the shank and that the silver has flown properly and that there are no gaps in the joint.

14] Set and grind the top rake angle, front clearance angle and side clearance angles  as per drawing and check.  

15] Carry out final inspection of the tools for dimensions and defects on carbide tips prior to painting.

16] Apply a cloth tape on the tips or hot dip the carbide tips in a plastic medium and wash the tools in a chemical that cleans, degreases and phosphates the shank prior to painting

17] Paint the tools and apply colour code at the back end to identify the grade.

Dark Blue for P20, light blue for P30, Red for K20 and Yellow for M20.

18] Pack the recessing tools in a suitable corrugated box and ship out.     

  

Raw materials Used:
1] Bright drawn steel rods of 30x20 mm to AISI 1018 specification.

2] Carbide tips as per ISO A 16 of P30 grade.

Procurement of Raw materials:
1] Procure steel rods from approved sources only along with material test certificates.

2] Procure carbide tips from the approved source in Europe or from Kennametal in India.

Inspection of Raw materials:
1] Carry out chemical analysis of the steel rods and check against specifications

2] Visually inspect the steel rods for defects such as cracks, deep dents and heavy scoring marks and clear materials if ok for all the above checks for manufacture.

3] Check the grade of the carbide tip to ascertain that the right grade is being used for manufacture of the tools.

Manufacturing Procedure.
1] Set and cut steel rods to lengths of 127+ 3 mm and check.

2] Set and mill the shank portion from 30 mm to 20 mm and create a head of 26 mm length and check.

3] Set and Mill the inside approach and clearance angle of the turning tools at 30 deg x0 deg and check.

4] Set and mill the outside approach and clearance angle of the turning tools at 30 deg x0 deg to maintain width of 12 mm at the front end of the shank and check.

5] Set and mill the front clearance angle of 5 deg x 8 deg to maintain front width at 14 mm.

6] Mill a positive top rake angle of 12 deg parallel to the front clearance angle to a width of 19 mm and maintain height over the front edge at 19 mm and check.

7] Set and mill the tip pocket of the cutting tool shank parallel to the top rake face and front approach angle to ensure that the carbide tip protrudes outside the steel shank by at least 0.8 mm, maintain height over carbide tips between 19.8 and 20.2 mm and C dimension at 9.8 to 10.2 and check.

8] De burr the cutting tool shanks and stamp the designation as ISO 6 R 2020 P 30 or as DIN 4980 R 20x20 P30 and check.

9] Carryout inspection of all operations done so far.

10] Grind the A 16 P30 carbide tips to remove the sintered surfaces on the brazing area.

11] Degrease the shanks of the turning tools and the carbide tips and ensure that the brazing area is free of rust.

12] Procure Silver foil of 0.1 mm thickness having min of 49% silver content and devoid of any Tin or Lead from Degussa in Germany or from an approved source in India

13] Apply suitable brazing flux on the tip seat area, build up a sandwich of 2 silver foils and a copper foil in between with brazing flux in between them and place them on the tip seat area, apply brazing flux to the area of the tip that gets brazed, place the tip to be brazed on top of the sandwich of foils. Allow to dry.

14] Set the Induction brazing machine with a suitable induction coil and power tapping points.

15] Insert the turning tool to be brazed with the carbide tip into the induction coil and start heating. Stabilise heating when the steel shank turns from blue to mild red in colour. Start heating again to take the carbide tip and the steel area surrounding it to the melting point of silver. Press the tip into position with a pointer rod and allow the turning tool to cool to about 200 deg C. Remove the tool from inside the induction coil and place it in pre heated sand and allow it to cool to the room temperature.

16] Inspect the joint to ensure that the carbide tip is brazed properly onto the shank and that the silver has flown properly and that there are no gaps in the joint.

17] Set and grind the top rake angle, front clearance angle, side clearance angle and corner radius of 0.8 mm on the carbide tips as per drawing and check.

18] Carry out final inspection of the tools for dimensions and defects on carbide tips prior to painting.

19] Apply a cloth tape on the tips or hot dip the carbide tips in a plastic medium and wash the tools in a chemical that cleans, degreases and phosphates the shank prior to painting.

20] Paint the tools and apply colour code at the back end to identify the grade. Dark Blue for P20, light blue for P30, Red for K20 and Yellow for M20.

21] Pack the turning tools in a suitable corrugated box and ship out

Raw materials Used:

1] Bright drawn steel rods of 30x20 mm to AISI 1018 specification.

2] Carbide tips as per ISO B 16 of P30 grade.

Procurement of Raw materials:

1] Procure steel rods from approved sources only along with material test certificates.

2] Procure carbide tips from the approved source in Europe or from Kennametal in India. Tectools a manufacture of Carbide tools & Lathe Tools sources its carbide from Europe.

Inspection of Raw materials:

1] Carry out chemical analysis of the steel rods and check against specifications

2] Visually inspect the steel rods for defects such as cracks, deep dents and heavy scoring marks and clear materials if ok for all the above checks for manufacture.

3] Check the grade of the carbide tip to ascertain that the right grade is being used for manufacture of the tools.

Manufacturing Procedure.

1] Set and cut steel rods to lengths of 127+ 3 mm and check.

2] Set and mill the shank portion from 30 mm to 20 mm and create a head of 22 mm length and check.

3] Set and Mill the inside approach and clearance angle of the turning tools at 35 deg x0 deg and check.

4] Set and mill the outside approach and clearance angle of the turning tools at 35 deg x0 deg to maintain width of 18 mm at the front end of the shank and check.

5] Set and mill the front clearance angle of 5 deg x 8 deg to maintain front width at  19 mm.

6] Mill a positive top rake angle of 12 deg parallel to the front clearance angle to a width of 13 mm and maintain height over the front edge at 19 mm and check.

5] Set and mill the tip pocket of the cutting tool shank parallel to the top rake face and front approach angle to ensure that the carbide tip protrudes outside the steel shank by at least 0.8 mm, maintain height over carbide tips between 19.8 and 20.2 mm and C dimension at 9.8 to 10.2 and check.

6] De burr the cutting tool shanks and stamp the designation as ISO 5 R 2020 P 30 or as DIN 4977 R 20x20 P30 and check.

7] Carryout inspection of all operations done so far.

8] Grind the B 16 P30 carbide tips to remove the sintered surfaces on the brazing area.

9] Degrease the shanks of the turning tools and the carbide tips and ensure that the brazing area is free of rust.

10] Procure Silver foil of 0.1 mm thickness having min of 49% silver content and devoid of any Tin or Lead from Degussa in Germany or from an approved source in India

11] Apply suitable brazing flux on the tip seat area, build up a sandwich of 2 silver foils and a copper foil in between with brazing flux in between them and place them on the tip seat area, apply brazing flux to the area of the tip that gets brazed, place the tip to be brazed on top of the sandwich of foils. Allow to dry.

11] Set the Induction brazing machine with a suitable induction coil and power tapping points.

12] Insert the turning tool to be brazed with the carbide tip into the induction coil and start heating. Stabilise heating when the steel shank turns from blue to mild red in colour. Start heating again to take the carbide tip and the steel area surrounding it to the melting point of silver. Press the tip into position with a pointer rod and allow the turning tool to cool to about 200 deg C. Remove the tool from inside the induction coil and place it in pre heated sand and allow it to cool to the room temperature.

13] Inspect the joint to ensure that the carbide tip is brazed properly onto the shank and that the silver has flown properly and that there are no gaps in the joint.

14] Set and grind the top rake angle, front clearance angle, side clearance angle and corner radius of 0.4mm on the carbide tips as per drawing and check.  

15] Carry out final inspection of the tools for dimensions and defects on carbide tips prior to painting.

16] Apply a cloth tape on the tips or hot dip the carbide tips in a plastic medium and wash the tools in a chemical that cleans, degreases and phosphates the shank prior to painting.

17] Paint the tools and apply colour code at the back end to identify the grade.

Dark Blue for P20, light blue for P30, Red for K20 and Yellow for M20.

18] Pack the turning tools in a suitable corrugated box and ship out     

 

Raw materials Used:

1] Bright drawn steel rods of 20x20 mm to AISI 1018 specification.

2] Carbide tips as per ISO C 20 in P30 grade.

Procurement of Raw materials:

1] Procure steel rods from approved sources only along with material test certificates.

2] Procure carbide tips from the approved source in Europe or from Kennametal in India.

Inspection of Raw materials:

1] Carry out chemical analysis of the steel rods and check against specifications

2] Visually inspect the steel rods for defects such as cracks, deep dents and heavy scoring marks and clear materials if ok for all the above checks for manufacture.

3] Check the grade of the carbide tip to ascertain that the right grade is being used for manufacture of the tools.

Manufacturing Procedure.

1] Set and cut steel rods to lengths of 127+ 3 mm and check.

2] Set and Mill the front clearance angle of the recessing tools at 0 deg x 8 deg and check.

3] Set and mill the side clearance angle on both sides of the recessing tools at 3 deg x8 deg to maintain width of 19 mm at the front end of the shank and check.

4] Mill a positive top rake angle of 12 deg parallel to the front clearance angle to a width of 20 mm and maintain height at the front corner at 19 mm and check.

5] Set and mill the tip pocket of the cutting tools & threading tools shank parallel to the top rake face and front approach angle to ensure that the carbide tip protrudes outside the steel shank by at least 0.8 mm, maintain height over carbide tips between 19.8 and 20.2 mm and check.

6] De burr the cutting tool shanks and stamp the designation as ISO 4 2020 P 30 or as DIN 4976 20x20 P30 and check.

Carryout inspection of all operations done so far.

7] Grind the C 20 P30 carbide tips to remove the sintered surfaces on the brazing area.

8] Degrease the shanks of the cutting tools and the carbide tips and ensure that the brazing area is free of rust.

9] Procure Silver foil of 0.1 mm thickness having min of 49% silver content and devoid of any Tin or Lead from Degussa in Germany or from an approved source in India

10] Apply suitable brazing flux on the tip seat area, build up a sandwich of 2 silver foils and a copper foil in between with brazing flux in between them and place them on the tip seat area, apply brazing flux to the area of the tip that gets brazed, place the tip to be brazed on top of the sandwich of foils. Allow to dry.

11] Set the Induction brazing machine with a suitable induction coil and power tapping points.

12] Insert the recessing tool to be brazed with the carbide tip into the induction coil and start heating. Stabilise heating when the steel shank turns from blue to mild red in colour. Start heating again to take the carbide tip and the steel area surrounding it to the melting point of silver. Press the tip into position with a pointer rod and allow the cutting tool to cool to about 200 deg C. Remove the tool from inside the induction coil and place it in pre heated sand and allow it to cool to the room temperature.

13] Inspect the joint to ensure that the carbide tip is brazed properly onto the shank and that the silver has flown properly and that there are no gaps in the joint.

14] Set and grind the top rake angle, front clearance angle, side clearance angle and corner radius of 1.2mm on the carbide tips as per drawing and check.  

15] Carry out final inspection of the tools for dimensions and defects on carbide tips prior to painting.

16] Apply a cloth tape on the tips or hot dip the carbide tips in a plastic medium and wash the tools in a chemical that cleans, degreases and phosphates the shank prior to painting.

17] Paint the tools and apply colour code at the back end to identify the grade. Dark Blue for P20, light blue for P30, Red for K20 and Yellow for M20.

18] Pack the cutting tools in a suitable corrugated box and ship out