How to machine tungsten carbide parts? A complete guide

Tungsten carbide - one of the hardest and most durable materials used in modern industrial processes. Its exceptional hardness (almost comparable to diamond) and wear resistance make it ideal for making tools, dies, cutting elements and other components subjected to high loads. However, these same properties make it difficult to machine. In this article, we'll look at the specifics of machining tungsten carbide parts and the key techniques used to achieve precision and quality.

Why is tungsten carbide so popular?

Tungsten carbide has unique properties that make it indispensable for a number of industries such as automotive, aerospace, mining and tooling. Key properties of tungsten carbide:

• High hardness: Comparable to the hardness of diamond, making it excellent for heavy duty applications.
• Wear resistance: The material retains its structure and shape even under prolonged high loads.
• Heat resistance: Tungsten carbide withstands high temperatures without any change in structure or properties.
• Corrosion resistance: Ensures durability of components in aggressive environments.

However, these advantages pose a challenge to manufacturers: how to process such a hard material efficiently? Let's look at the main methods of tungsten carbide processing.

Tungsten carbide processing methods

1. Grinding with diamond tools

One of the main methods for machining tungsten carbide is grinding with diamond tools. Diamond wheels are the most suitable for machining this material due to their hardness and ability to withstand high loads.

The sanding process includes the following steps:

• Grinding wheel selection: Normally a diamond abrasive wheel is used. The choice of the correct size and grit depends on the required machining accuracy.
• Cooling accuracy: It is important to control the temperature during sanding, as overheating can cause micro-cracks in the material.
• Tilt angle: Grinding angles and geometry play a key role in ensuring correct shape and reducing defects.

Grinding with diamond tools allows for high precision performance, but this method requires high skill and attention to detail to avoid damage to the material.

2. Electrical discharge machining (EDM)

Electrical discharge machining - is another common method used for machining tungsten carbide, especially when high precision or complex part shapes are required. EDM is particularly effective for machining very hard materials such as tungsten carbide.

The main steps in the process are:

• Electrode: A wire is used as an electrode through which an electric current is passed. This produces a spark which melts and vaporizes the material.
• Parameter control: The accuracy of the process depends on the correct setting of parameters such as electrode feed rate and current.
• Cooling: A dielectric fluid is used to prevent the part from overheating, which also helps to remove process waste.

EDM allows for high accuracy in the production of complex shapes, but the process requires the use of specialized equipment and control at every stage.

3. Laser treatment

Laser treatment Tungsten carbide is a technique that is used for cutting, drilling and creating complex shapes. This process is used where maximum precision and minimal impact on the material is required.

Laser processing:

• Laser beam: A high-energy laser beam is directed at the surface of tungsten carbide, causing it to melt or vaporize.
• Parameter control: Adjustment of laser power and beam speed allows for precise machining.

Advantages of laser processing:

• Small heat-affected zone, which reduces the risk of deformation.
• High precision and minimal waste.
• Ability to machine complex shapes and fine details.

4. Chemical and thermal exposure

Tungsten carbide can also be treated using special chemical solutions or by heat treatment. These methods are used to improve wear resistance and extend component life.

Problems when machining tungsten carbide

In spite of all modern technology, tungsten carbide processing is fraught with a number of challenges:

1. Tool wear: Due to the high hardness of tungsten carbide, cutting and grinding tools wear out quickly.
2. High temperatures: Machining tungsten carbide requires cooling, as high temperatures can cause micro-cracks or changes in the structure of the material.
3. Slow process: Compared to machining softer materials, the tungsten carbide machining process is much slower, which can increase production costs.

Applications of tungsten carbide

Tungsten carbide is widely used in the following industries:

• Automotive industry: Manufacture of dies, engine parts and cutting tools.
• Mining industry: Drilling rigs, cutting tools and parts subject to high wear.
• Production of cutting tools: Includes drills, cutters and bits for machining hard materials.

Tungsten carbide machining is a complex and technically demanding process that requires the use of specialized equipment and highly skilled personnel. Techniques such as diamond grinding, electrical discharge machining and laser cutting enable the creation of highly accurate and durable parts for various industries. Despite the challenges, tungsten carbide remains an indispensable material in modern manufacturing due to its unique properties.

Company Yize Mould specializes in machining precision tungsten carbide parts and is ready to offer our customers high quality solutions for demanding applications. Contact us for more information and to discuss your project.