Cemented Carbide Cold Heading Die Nibs CERATIZIT – the Parent Companies
Total Page：16
File Type：pdf, Size：1020Kb
Cemented carbide cold heading die nibs CERATIZIT – the parent companies Headquarters and main site Main site REUTTE / Austria MAMER / Luxembourg Hard material matters – it is the Production plants in the three We promote intensive dialogue core of our business. Through main economic areas and a with our customers and strive for profound knowledge and highly worldwide sales network of sub- long-term business relations on flexible production facilities we sidiaries and distribution part- a partnership basis. strive to provide our business ners ensure a quick response to The CERATIZIT corporate value partners with direct competitive customer needs. In-house trai- ‘The focus and point of view advantages in the field of hard nings and seminars guarantee of our business partners mat- materials for tooling solutions that both business partners and ters’ is a guiding principle for all and wear parts. Our dedication employees share the latest infor- CERATIZIT employees world- to hard material matters creates mation on our product range. wide. intelligent solutions for tomorrow and time to come. Europe • Austria • Bulgaria • Czech Republic • France • Germany • Hungary • Italy • Luxembourg • Netherlands • Poland • Switzerland • Spain • United Kingdom North America • USA Asia • China • India • Japan South America • Brasil Direct sales and distribution partners 2 CERATIZIT - Hitzacker CERATIZIT Hitzacker was founded in 1985. It is a company operating on an international level and specializing in the manufacture of cemented carbide blanks and semi-finished products for the metal forming sector. Our strength is the production of individual single pieces and small batch manufacture according to customer drawings with extremely short lead times of between 2 and 3 weeks. Consistent top quality of our carbide products is something that we take for granted. With the help of our express production line we can even reach delivery times of below 2 weeks in urgent cases. Our qualified staff guarantee high quality processing and accurate delivery performance to ensure a high degree of customer satisfaction. Our grinding centres focus on circular grinding up to a diameter of 200 mm, internal grinding from 6 mm diameter onwards and, naturally, surface grinding. 3 Carbide production Carbide is a composite material consisting of particles mainly with tungsten carbide as hard material and a metallic binder. For this reason, with carbide it is possible to achieve hardness and toughness combinations which cannot be obtained with other materials. The graphic illustration below shows the basic steps for producing carbide blanks in the metal forming sector. Powder preparation Due to its high melting point tungsten carbide (WC) can only be produced through sintering when needed for technically sophisticated applications. For this purpose, the powder consisting of the tungsten carbide, the cobalt binder (Co) and sometimes additional alloys, is mixed, milled and spray-dried. This process results in a spray-dried granulate which can easily be used for production, since its chemical and physical properties have already been adapted to the final carbide specification (e.g. WC grain size). Co (NI,Fe) Tungsten oxide TiC, TaC, NbC Cr C , VC, MoC Tungsten 3 2 Reduction Tungsten carbide Carburising Mixing Milling Granulation HartmetallpulverCarbide powder Granulatgranulate 4 Carbide production Manufacture and machining of blanks By applying pressure the carbide powder is converted into a blank. The material will receive its near net shape through the application of traditional machining methods (sawing, drilling, milling, turning), so that extended machining of the sintered carbide blank is no longer necessary. The density of the blank is approx. 50% of the sintered carbide‘s density which leads to an approx. 20% shrinkage in length. Die Isostatic pressing pressing (cold) Optional: machining of blanks Sintering The sintering process converts the blank into a homogeneous piece of carbide with a high degree of hardness. When sintering hard metal (usually at a temperature of approx. 1400°C), this process is called liquid phase sintering. In this case, the binder (e.g. cobalt) melts and wets the WC hard material particles. After sintering, the density of the carbide is almost, or even precisely, the same as the theoretical density. Any residual porosity which occurs after the sintering procedure may be removed through an ensuing HIP process. Sintering Blanks Turning/drilling Grinding (only grades with a high Co content) Erosion (wire and plunge) Honing/polishing Further processing 5 Hard materials / carbide Carbide is a brittle, hard material with mechanical properties that can be adjusted within a very wide range, given its composition and microstructure. The hardness and toughness range of the CERATIZIT grades includes everything from wear resistant tool steel to super-hard ceramic materials. 6 The basis for optimum quality The graphic illustrations below show that the mechanical properties of the carbide mainly depend on the binder content (Co) and the TC grain size. Hardness, i.e. wear resistance, increases inversely/reciprocally proportional to the fracture toughness. This means that the harder the material the more it reacts to notch tensions and impact stress (the ‘impact resistance’ parameter, which cannot be precisely defined, correlates to a high degree with the fracture toughness of the material). On the other hand, the transverse rupture strength does not directly depend on the hardness but rather on the TC grain size and the cobalt content. The adhesive wear (tendency to stick), however, decreases with the grain size and the cobalt content of the carbide used. The list of the mentioned interdependencies, which could be extended at will for other wear and failure mechanisms, show that it is only possible to choose the correct carbide grade following a systematic procedure and/or based on experience with similar forming processes. Submicron grain Fine / medium grain Hardness [HV30] Submicron grain Coarse grain Submicron grain Fine / medium grain Fine / medium grain Coarse grain Transverse rupture strength [MPa] Transverse ] Coarse grain 1/2 Submicron grain -value [MPa*m -value IC Fine / medium grain Coarse grain Toughness K Toughness 7 Carbide grade overview The following graph is intended as a guideline to show which grades can be successfully applied for the corresponding metal forming processes. It should, however, be taken into consideration that, in addtion to the correct grade selection, a consistently high metallurgical quality is a prerequisite for long tool life. Use the knowledge and experience of your CERATIZIT contact person to optimize tool life by utilizing the correct carbide grade! Compound heading, Semi-hot/ Cold heading dies extruding and shaping hot forming tools punches Grades CT- Grade- code High toughness Medium toughness resistance Medium wear resistance High wear High toughness Medium toughness resistance Medium wear resistance High wear shock High thermal shock Medium thermal shock thermal Low Submicron grain MG18 CTS20L GC05 CTF11E GC10 CTF12E GC15 CTM17A Fine / medium GC20 CTF24E grain GC30 CTF30E GC37 CTF40A GC55 CTF50A GC62 CTF54A GC32 CTC20A GC40 CTC30A GC50 CTC35A Coarse grain GC60 CTC40A GC65 CTC50A GC70 CTC60A Blanks with grinding allowance: External, internal diameter and length are ready-for-use dimensions with grinding allowance (and sintering tolerances). Semi-finished products: External diameter and length are ground. 8 Carbide grades Composition and properties Transverse rupture Grade CT- ISO K Code Appli- Binder Hardness KIC* Grade cation strength SEVNB code fi eld (%) HV10 HV30 HRA MPa P.S.I. MPa*m1/2 SUBMICRON GRAIN MG18 CTS20L K20-40 10.0 1680 1660 92.3 3700 537.000 9.4 FINE / MEDIUM GRAIN GC05 CTF11E K10 G05 5,6 1760 1730 92,7 2150 312,000 9,2 GC10 CTF12E K20 G10 6.0 1630 1610 92.0 2200 319.000 9.9 GC15 CTM17A K30 G15 8.5 1420 1400 90.5 2800 406.000 11.3 GC20 CTF24E K40 G20 12.0 1330 1320 89.7 3000 435.000 12.0 GC30 CTF30E >K40 G30 15.0 1250 1240 88.8 3100 450.000 13.1 GC37 CTF40A G40 20.0 1100 1090 87.3 3400 493.000 14.2 GC55 CTF50A G50 25.0 950 940 85.3 3400 493.000 15.2 GC62 CTF54A G55 27.0 920 910 85.0 3200 464.000 15.7 COARSE GRAIN GC32 CTC20A G15-G20 10.0 1180 1170 88.1 3000 431.113 15.6 GC40 CTC30A G30 15.0 1060 1050 86.7 3150 457.000 17.3 GC50 CTC35A G30-G40 17.5 1000 990 86.0 3200 464.000 17.9 GC60 CTC40A G40 20.0 930 920 85.1 3200 464.000 18.6 GC65 CTC50A G50 25.0 840 830 84.0 3200 464.000 21.1 GC70 CTC60A G55 30.0 750 740 82.9 3200 464.000 22.5 Comments: 1. The data in this table are typical material parameters. We reserve the right to modify the data due to technical progress or due to further development within our company. 2. KIC*: The measured critical tension intensity factors (KIC) depend to a high degree on the sample geometry and sample preparation. A direct comparison with parameters which have been determined by means of a different method is therefore not admissible. 9 Sintering tolerances State-of-the-art machines enable us to produce round parts with diameters ranging from 4 mm to 200 mm and lengths of up to 250 mm. As for prismatic components, the maximum dimensions manufactured are l=250 mm, b=100 mm (width) and h=42 mm. We will gladly make you an offer for special dimensions. External diameter Length [mm] [mm] from - to <19 20 - 35 35 - 50 55 - 80 90 - 120 >140 10 - 14 0.4 - 1.0 0.4 - 1.1 0.4 - 1.1 0.4 - 1.2 15 - 18 0.4 - 1.1 0.4 - 1.2 0.4 - 1.3 19 - 24 0.4 - 1.3 0.4 - 1.3 0.4 - 1.4 0.5