UKO introduced cermet insert, it always advocated that cermet can help mold processing workshops reduce production cost. And this is not just because our cermet price is lower than that of cemented carbide. Let me explain cermet inserts vs carbide to you in detail.
First, you can replace multiple operations with one operation. When the metal ceramic insert is used for hard milling, the steel parts can be quenched first, and then the workpiece can be milled in the hardened state, so as to replace the three processes of processing → quenching → reprocessing. By reducing the installation and handling time of workpieces in different processing stages, the processing cycle can be shortened and the operation path can be improved. In addition, rough milling of hardened workpieces with ceramic inserts can avoid expensive and time-consuming EDM (electric discharge machine tool) machining, without the need to make one or more electrodes.
Second, the ceramic insert can process hardened steel at a much higher speed than the traditional carbide tool. By combining high processing speed, proper feed rate and correct operation time, the metal removal rate of the machining workshop can be impressive. Another key factor to improve productivity in hard milling is the cutter tooth density. The crossfeed rate will be increased for each additional tooth on the tool. Higher cutting speed and higher feed rates will result in a shorter machining cycle and less money.
Thirdly, the machining surface obtained by rough milling of the ceramic insert can often reduce the machining allowance of finish milling, thus reducing the time required for finish milling and polishing. When the hardened steel is milled with a carbide insert at a relatively small feed rate, a good surface finish is usually obtained, but in many cases, the surface finish of rough milling with a ceramic insert is even better than the required surface finish. In some cases, additional finishing, grinding and polishing can be saved, thus saving a lot of man-hours.
All in all, the advantages of cermet milling inserts, such as shortening machining cycle, reliability and indexability of inserts, reusability of CNC tool holder and excellent surface finishing ability, show impressive potential in improving productivity and saving cost. Getting higher productivity at less cost means that the mold shop can produce more products, which is a good thing.