Raw materials Used:
1] Bright drawn steel rods of 30×20 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.
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 20×20 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