The Tungsten/Copper alloys mainly consists 2% to 40% of copper. By adding up of copper, thermal conductivity of the alloy increases while reducing the modulus and hardness of rupture.
The grinding and machining characteristics of copper/tungsten alloys are similar to hard cast iron. These alloys are non-porous therefore standard water soluble coolants are used in their machining. Every manufacturing industry usually has its own individual grinding or machining practice centers. Therefore, machining tungsten or copper can only be performed after proper practicing. Strict professional guidance should be followed during machining process.
Tools and Processes Used For Machining Tungsten/Copper Alloy:
Tools: Carballoy grade 883 or equivalent, grind tools with 0 deg rakes, 8-12 deg clearance, and .010" to .025" nose radius are used for machining the alloy.
The nose radius can be increased with the size of the work. For the excellent finish, stone small flat or parallel tool method can be used. It is advisable to rest stone on alloy piece when honing tools.
Shaping: For perfect shaping of Tungsten- Copper alloy the tool speed should be 43" per minute.
Feed: Feed rate should be 0.020" per stroke.
Boring & Turning: Roughly, 0.030" deep and 0.020" per revolution is made on the alloy surface. Finishing of about 0.002" to 0.005” should be done. Turning speed required is 300-450 surface feet per minute. Avoid the use of coolant or lubricant while machining these alloys.
Milling: For the milling process taps and high Speed steel drills may be used.
Depth of Cut: For tungsten-copper alloy the deep cut should be kept up to 0.40".
Tapping: Straight and accurate holes can be created by using tapping process. Material must be tightly held. Hand feed-lubricant and cutting oil can also be used for perfect cutting.
Rough Grinding: Rough grinding is done with 80 grit resin bonded wheels of medium hardness. Use water or water soluble oil as a coolant.
Joining: After the machining process these alloys can be copper brazed or silver brazed in a hydrogen environment.
The grinding and machining characteristics of copper/tungsten alloys are similar to hard cast iron. These alloys are non-porous therefore standard water soluble coolants are used in their machining. Every manufacturing industry usually has its own individual grinding or machining practice centers. Therefore, machining tungsten or copper can only be performed after proper practicing. Strict professional guidance should be followed during machining process.
Tools and Processes Used For Machining Tungsten/Copper Alloy:
Tools: Carballoy grade 883 or equivalent, grind tools with 0 deg rakes, 8-12 deg clearance, and .010" to .025" nose radius are used for machining the alloy.
The nose radius can be increased with the size of the work. For the excellent finish, stone small flat or parallel tool method can be used. It is advisable to rest stone on alloy piece when honing tools.
Shaping: For perfect shaping of Tungsten- Copper alloy the tool speed should be 43" per minute.
Feed: Feed rate should be 0.020" per stroke.
Boring & Turning: Roughly, 0.030" deep and 0.020" per revolution is made on the alloy surface. Finishing of about 0.002" to 0.005” should be done. Turning speed required is 300-450 surface feet per minute. Avoid the use of coolant or lubricant while machining these alloys.
Milling: For the milling process taps and high Speed steel drills may be used.
Depth of Cut: For tungsten-copper alloy the deep cut should be kept up to 0.40".
Tapping: Straight and accurate holes can be created by using tapping process. Material must be tightly held. Hand feed-lubricant and cutting oil can also be used for perfect cutting.
Rough Grinding: Rough grinding is done with 80 grit resin bonded wheels of medium hardness. Use water or water soluble oil as a coolant.
Joining: After the machining process these alloys can be copper brazed or silver brazed in a hydrogen environment.