Industrial Brazed Tools

1. What are Industrial Brazed Tools?

Industrial brazed tools are cutting tools in which the cutting edge or inserts (often made of carbide, cermet, or other hard materials) are brazed or attached to a tool holder or body using a strong metal filler material. The brazing process helps create a permanent bond between the cutting material and the tool body, providing greater strength, wear resistance, and performance under demanding machining conditions.

These tools are used across a wide range of industries for tasks such as turning, milling, drilling, and shaping various materials, including metals, plastics, and composites.

2. Brazing Process for Tool Manufacturing

The brazing process involves several steps:

• Preparation of Materials: The tool body (usually steel or another durable material) and the cutting insert (carbide, cermet, or other hard alloys) are cleaned and prepared. Any oxidation or contaminants are removed to ensure a strong bond.

• Application of Flux: A flux is applied to the surfaces to be joined to prevent oxidation during the heating process and to facilitate the flow of the filler material.

• Heating: The parts are heated to a temperature that is sufficient to melt the filler material but not the base metals. This is typically done in a furnace or with a torch. The filler material melts and flows into the joint, bonding the cutting edge to the tool body.

• Cooling and Finishing: After brazing, the tool is cooled, and any excess flux or filler material is cleaned off. The brazed tool may undergo additional finishing processes, such as grinding, to achieve the desired shape, sharpness, and accuracy.

3. Types of Brazed Tools

Brazed tools come in a variety of configurations, each suited to specific machining tasks. Some common types include:

• Brazed Inserts: These are small, high-performance cutting tips brazed onto tool bodies. They are commonly used for turning, milling, and other machining operations. The insert can be made from materials like carbide or cermet for high wear resistance.

• Brazed Drills: Drilling tools where the cutting edges are brazed to the body of the drill. Brazed drills are ideal for drilling applications requiring high precision and the ability to handle tough materials.

• Brazed Reamers: Reamers with brazed carbide or cermet inserts are used for finishing holes to tight tolerances. The brazed inserts offer durability and a smooth finish.

• Brazed Cutting Tools for CNC Machines: CNC (Computer Numerical Control) machines use high-precision brazed tools that are designed to meet the specific needs of automated machining operations, such as milling, drilling, or turning operations with high-speed rotation.

• Brazed Tool Holders: These tools feature brazed inserts or cutting edges that are fixed into holders, providing the operator with flexibility for different operations. They are commonly used in industrial applications like metalworking and woodworking.

4. Materials Used for Brazing

The choice of materials used in brazing is critical to the tool’s performance. Common materials include:

• Carbide: Tungsten carbide inserts are commonly brazed onto tool bodies due to their extreme hardness, wear resistance, and ability to cut through hard materials.
• Cermet: A combination of ceramic and metallic materials, cermets are often used for high-speed cutting and provide excellent wear resistance and heat tolerance.
• High-Speed Steel (HSS): Used for cutting tools that need toughness and flexibility, HSS is often brazed with carbide inserts for enhanced cutting performance.
• Ceramics: For high-temperature operations, ceramic inserts are brazed to tool bodies to provide resistance to heat and wear.
• Brazing Alloys: The filler material used for brazing can be made from alloys such as silver, copper, or nickel, depending on the application and materials being joined.

5. Advantages of Brazed Tools

Brazed tools offer several advantages over other types of cutting tools:

• Improved Tool Life: The brazing process allows for the attachment of harder, more wear-resistant materials (like carbide) to the tool body, resulting in a longer tool life.
• Cost-Effective: Brazing allows manufacturers to use less expensive materials for the tool body while still achieving high-performance cutting edges. It is a cost-effective way to produce durable, high-quality tools.
• Enhanced Cutting Performance: Brazed tools typically provide superior cutting performance, as the high-quality materials used for the inserts or cutting edges can withstand high temperatures, pressures, and wear.
• Reduced Tool Wear: The use of materials like carbide or cermet in brazed tools reduces tool wear significantly, leading to fewer tool changes and more consistent machining.
• Versatility: Brazed tools can be made in various shapes and sizes, making them suitable for a wide range of machining operations, from simple turning to complex milling or drilling tasks.

6. Applications of Industrial Brazed Tools

Brazed tools are used in numerous industrial applications, including:

• Metalworking: Brazed cutting tools are frequently used in metal machining operations such as turning, milling, drilling, and boring. They are especially useful for cutting hard metals, alloys, and steel.
• Automotive Manufacturing: The automotive industry uses brazed tools for producing engine parts, gears, shafts, and other components that require high precision and wear resistance.
• Aerospace: In aerospace manufacturing, brazed tools are used to machine materials like titanium, high-strength steels, and aluminum alloys, which require tools that can withstand high temperatures and pressures.
• Tool and Die Making: Brazed cutting tools are employed in creating molds, dies, and punches, where both hardness and precision are required.
• Woodworking: In woodworking, brazed tools are used for shaping, turning, and cutting wood products.
• Construction and Mining: Tools used for cutting and shaping hard materials in construction and mining operations often utilize brazed cutting edges to improve their durability and performance.

7. Factors to Consider When Choosing Brazed Tools

When selecting brazed tools for a particular application, several factors need to be considered:

• Material Compatibility: The workpiece material should be compatible with the brazed tool’s cutting edge to ensure efficient cutting and reduce tool wear.
• Tool Geometry: The shape and geometry of the tool are critical for achieving the desired cutting performance. Different shapes of inserts, cutting angles, and tool holders are designed for specific operations.
• Cutting Conditions: The speed, feed rate, and type of operation (turning, milling, drilling, etc.) should align with the brazed tool’s design to ensure optimal performance.
• Tool Coatings: Some brazed tools feature coatings like TiN (Titanium Nitride) or TiCN (Titanium Carbon Nitride) to enhance wear resistance, reduce friction, and improve tool life.
• Cost vs. Performance: While brazed tools may have a higher upfront cost due to the materials used, they often provide longer tool life and better performance, making them a more economical choice in the long term.

8. Maintenance of Brazed Tools

Proper maintenance can extend the life of brazed tools and ensure consistent performance:

• Cleaning: After use, brazed tools should be cleaned to remove any debris, cutting chips, or material buildup that could affect performance.
• Inspection: Regular inspections should be conducted to check for wear, cracks, or damage to the brazed joints or cutting edges.
• Sharpening: Over time, the cutting edges of brazed tools may dull. Professional sharpening can restore the tool to its optimal cutting condition.
• Storage: Brazed tools should be stored in a dry, clean environment to prevent rusting or degradation of the brazed joint.

Conclusion

Industrial brazed tools play a critical role in manufacturing processes, offering an excellent balance of durability, cost-effectiveness, and performance. By brazing hard, wear-resistant materials like carbide or cermet to tool bodies, these tools provide superior cutting performance and longer tool life. With applications across various industries, including metalworking, automotive, aerospace, and tool-making, brazed tools are a vital component for high-precision and high-performance machining operations. By understanding their advantages, types, and proper maintenance, manufacturers can optimize their production processes and achieve consistent, high-quality results.