Material Machining Views: 10

Copper and copper alloy notes plus anti-welding methods: Characteristics: 1) High ductility - ribbon chips that tangle around tools and workpieces; 2) Welding - easy sticking (built-up edge), especially at low speed: poor finish, unstable size; 3) Good thermal conductivity - heat dissipates, tool stays cool, low wear; 4) Low hardness - low cutting force, long tool life; 5) Easily deformed - low strength and rigidity: thin walls deform. Which tool: 1) Standard HSS - usable, cheap, long life; 2) Cobalt HSS (HSS-E) - more wear-resistant: batches; 3) Carbide - most wear-resistant for high volume, but somewhat wasted on soft copper; 4) Coating - DLC is best (low friction, anti-welding) for copper and aluminum; TiAlN works but anti-welding is worse; 5) Uncoated - polished bright uncoated tools also resist welding. Parameters: 1) speed - high: cobalt HSS 1500-3000rpm, carbide 2000-4000rpm; 2) feed - medium-high, 0.12-0.25mm/rev; 3) fluid - semi- or full synthetic, 3%-5%, or kerosene/copper-specific fluid: good lubrication, anti-welding; 4) avoid low speed - BUE forms at low speed; use medium-high speed (BUE range generally 50-200rpm). Anti-welding: 1) DLC-coated tools - best; 2) medium-high speed - avoid the BUE range; 3) sharp tools - very sharp, polished edges; 4) generous cooling - lubricating fluid, flood; 5) clean chips promptly - prevent tangling; 6) polished tool surfaces - mirror finish reduces friction and sticking. Notes: 1) prevent deformation - thin copper parts deform: light clamping, not too tight, add support; 2) anti-welding - DLC or high speed; 3) anti-tangling - ribbon chips: chip-breaker tools or clean promptly; 4) measuring - copper expands with heat: cool before measuring; 5) surface - soft and easily scratched: protect after machining, do not mix with other parts. Copper is an easy material - DLC-coated or cobalt HSS with high speed and generous cooling gives bright chamfers. Ask our technical team.