Ceramics for smart and productive machining of super alloys. Cutting wheel cutting is the most satisfactory method of cutting glass mica composites. Macor is a good thermal insulator and is stable up to temperatures of c, with very little thermal expansion or outgassing. Custom high precision cnc macor, titanium and ceramic machining services. Use a carbide grit blade at a band speed of 100fpm. Macor machinable glass ceramic mgc general information. Turning speeds are adjusted to the feed rate of the mini lathe 0. This information gives a basis for good machining practice, but do not be afraid to experiment with tools and speeds to obtain the optimum machining performance from your equipment. Machinable ceramics micatron machinable ceramic, ceramic. Save time and money by downloading and printing the speeds and feeds table for your specific tool, and simulate its running parameters and tool paths by accessing our complete library of simulation files. It is normally the requirement to maintain a surface finish which controls machining speeds. Speed is limited to 15mmin 50 sfpm when using high speed steel cutters. Machine and manufacture your own macor machinable glass. The materials investigated were macor and boron nitride and the machining operation was a continuous operation turning.
Macor ceramics ceramic machining, advanced ceramics. An alternative is a silicon carbide or diamond cutoff wheel. Using the data tables and the milling formulas below, you can calculate the speeds and feeds of any carbide end mills and diamond end mills. Machining machining 6 key factors for successful machining are proper machining speeds and coolant.
Essential factors for successful processing of macor are proper machining speeds and the selection of a suited coolant. Ceramic milling typically runs at 20 to 30 times the speed of carbide, although at lower feed rates 0. Speeds and feeds are only general starting points and may vary depending on specific applications. An experimental study on rotary ultrasonic machining of macor ceramic. Key factors for successful machining are proper machining speeds and coolant. Ukam industrial superhard tools specializes in manufacturing precision diamond tools for advanced and technical ceramics industries. Macor macor is a machinable glass ceramic made by corning incorporated. Use a bonded siliconcarbide type abrasive cutoff wheel. There are many compositions for different applications. Macor properties, macor machining ceramic substrates. Macor machinable glass ceramic can be machined with high speed tools, but carbide tools are strongly recommended for longer wear and better finishes.
Macor machinable glass ceramic high temperature machinable. With costcontainment as a driver, the average shop needs only to learn some of the basics to start machining the machinable class of ceramic material like macor, alumina silicate, boron nitride and other glass mica composites make up the majority of this class. The glassceramic can be processed with conventional hss tools, although we recommend using carbide tools for more extended wear. See how macor glass ceramic is machined morgan technical. Best results achieved by using a watersoluble coolant such as cimstar 40 pink especially formulated for cutting and grinding glass or. Macor machinable glass ceramic is a white, odourless, porcelainlike in appearance material composed of approximately 55% fluorophlogopite mica and 45% borosilicate glass. To investigate surface roughness in rum of macor dental ceramic material, feed rate, spindle speed, ultrasonic power, and coolant pressure were selected as four process variables, as represented in table 3.
Climb milling prevents material being pulled off the edge of the macor. Cutting speed 9 to 45mmin 30 to 150 sfpm using carbide tools. Macor can be machined with high speed steel tools but the use of tungsten carbide tools is highly recommended ceramic tipped tools are not advised. Macor machinable glass ceramic distributor and supplier for over 10 years and therefore has built up considerable expertise in the applications of macor along with techniques to machine the material into complex shapes. Macor is a machinable glass ceramic material that possesses outstanding engineering properties. Macor machining micatron machining macor, aerospace. Macor machinable glass ceramic can be processed with tools of. Macor consists of interlocking platelike mica crystals in a glassy matrix. The speeds and feeds calculator uses the following. Milling operations remove material by feeding a workpiece into a rotating cutting tool with sharp teeth, such as an end mill or face mill. Machining a mini production run of macor, a glass ceramic machinable composite, on the tormach 440. Macor machinable glass ceramic can be machined with high speed steel tools, but.
At the speed of 1681 rpm, the recommended feed rate is 235340. So, too, can carbide and ceramic cutting tools achieve higher speeds regardless of the workpiece material than do ones made of high speed. This video details some of the machining processes used by mtc wesgo duramic in the working of macor glass ceramic. Macor machinable glass ceramic can be machined with high speed steel tools, but carbide tools are recommended for longer wear. Softer metals like aluminum and mild steel have higher cutting speeds than do nasty metals like titanium or inconel. Achieve the best results by using a watersoluble coolant, such as cimstar 40 pink, especially. Calculate the speeds and feeds of carbide end mills, diamond end mills, and plastic cutting carbide end mills with these general machining guidelines. It can be machined using high speed steel and carbide tools, with the latter being preferred due to longer service life. Macor ceramic machines differently from metal, but an experienced machinist should be able to achieve excellent results after becoming familiar with the material. This problem solving material combines the performance of a technical ceramic with the versatility of a high performance plastic. Typical head speeds are 1500 rpm with a chip load of 0. We understand the problems you are facing in machining advanced ceramics and stepped up to meet this challenge by developing precision diamond products and technology that will help achieve closer tolerances, faster material.
Find macor machining tips related suppliers, manufacturers, products and specifications on globalspec a trusted source of macor machining tips information. Ceramic machining applications ceramic grades can be applied in a broad range of applications and materials. The shop relies on its years of experience working with ceramic material to understand and control critical variables that can affect part production. Nov 22, 2008 key factors for successful machining are proper machining speeds and coolant. Determine the spindle speed for turning, milling, drilling, and reaming with these charts and cutting speed calculators. Machinable glass ceramic sample preparation and machining.
This is a one piece order, and we dont cut this stuff very often. Any ideas for speeds feeds and depth of peck for that. High use temperature nonflammable excellent electrical insulator excellent thermal insulator dimensionally stable. Work slowly and steadily, do not force the tools, and keep tool speed to suggested levels. It can be machined to a surface finish of less than 0. Building on cornings 160 years of innovation, macor machinable glass ceramic is a solid, trusted foundation that can help you realize your designs quicker. Macor machinable glass ceramic can be machined with high speed tools.
Jan 29, 2009 however, successful machining requires more than machines with exceptional capabilities. This problem solving material combines the performance of a technical ceramic with the versatility of a. The specific properties of each ceramic grade enable high productivity, when applied correctly. Harvey tool speeds and feeds guide general machining. Dec 23, 20 milling macor on our haas vf3 using a garr vrx endmill. Because macor is a brittle material, we recommend using soft jaws to help distribute the load.
As a premier macor distributor, ceramic products can offer assistance in applying this unique material to solve your specific engineering needs. The most important factors when machining macor are using proper machine speeds feeds and coolant amounts. Although macor can be readily machined by using standard tools which are normally available to the average engineering shop, macor can also be machined in a far more costeffective manner, a far more efficient manner, by using machines and cutting tools which are designed for machining macor. Macor can be machined to make precision components but its machining. Composition 7 microstructure of macor mgc 5000x magnification. Macor machinable glass ceramic glass ceramics industrial. How to determine cutting speeds for machining tools dummies. Prototype, cnc production, manual and 3 and 4axis machining services are available. Solid round tool speeds and feeds kyocera precision tools. It is these crystals which stop microscopic fractures at the tool tip from spreading through the material, thus making it. The impact of different input factors, namely spindle speed, feed rate, coolant pressure, and ultrasonic power, has been evaluated on the process responses of. Machining macor into complex parts with tight tolerances means it can be adapted to a wide variety of applications.
Cutting acrylic 8 guidelines to get the best results acrylic is a great material to work with on your cnc system, as there is so much you can do with it, from lighted edgelit signs to coollooking inserts for speaker boxes, and other projects that need some bling. Click to download macor technical specifications pdf. Macor is the trademark for a machineable glassceramic developed and sold by corning inc. Macor machinable glass ceramic can be processed with tools of highspeed steel to achieve a longer service life and better surface finishes, cemented carbide tools are recommended. For holes up to about o 5mm a spindle speed of 1500 rpm and a feed rate. Shapal him soft is a hybrid type of machinable aluminum nitride ceramic that offers high mechanical strength and thermal conductivity. The drill feed rate should be chosen to suit the hole diameter and macor workpiece thickness. Machinability assessment of two ceramic materials was carried out using uncoated carbide tool inserts under dry conditions. The manufacturer doesnt recommend coolant on a drill that small, just a full retract between pecks. Pdf an experimental study on rotary ultrasonic machining.
Due to intermittent cutting, it is a much cooler operation than turning. Its unique combination of properties makes it an easily machinable, versatile, and high performing material even in harsh operating environments where precision is a necessity. Additionally, materials like silicon carbide sic may not fit the precise definition of a ceramic material, but they can still be classified as part of the ceramic family. I have to calculate the spindle speed and feed rate for machining special material called macor machinable ceramic. It can be machined using standard metalworking tools. It is machined with high speed steel or, more easily, with carbide tooling at relatively low speeds and feeds, but with greater depth of cut than is usual with metals. Achieve the best results by using a watersoluble coolant especially formulated for cutting and grinding glass or ceramics.
No longer is it necessary to staff a ceramic specialist with high temperature kilns. In the present experimental study, macor dental ceramic has been selected as a work material with the dimensions of 50. Macor machinable glass ceramic for industrial applications machining guidance key factors for successful machining are proper machining speeds and coolant. Macor can be quickly, accurately and economically machined into highprecision components using ordinary metalworking tools and does not require any postfiring after machining has been completed, removing a production process, reducing manufacturing. Remember, you are machining a brittle material so always avoid physical shock.
Once in slab form it is cut into smaller blocks and machined into into bars, tubes, disks or. Macor ceramic guide key factors for successful machining are proper machining speeds and coolant. Macor machinable glass ceramic mgc production machining. After sizing the material, ill stand it up in the vise, and drill the. Macor machining guidelines the key factor for successful machining of macor is to utilize proper machining speeds and coolant. The producer of macor recommends the following machining parameters. The objectives of this investigation were to generate reliable machining data in terms of. Feed rates are 2030 mm minute with a depth of cut of 24mm for roughing and less than 1mm for finishing. All cutting tools have a recommended cutting speed for any given material.
Although macor is a high temperature material, the best machining results are obtained when both the material and tool. It is also recommended that water soluble cutting oils designed for glass and ceramics are used when machining macor. By combining aluminum nitride with boron nitride, tokuyama has created a ceramic that is easily machined into complex shapes while still keeping many of the advantages of traditional aluminum nitride. When first machining macor, try using lower machine speeds and smaller cut depths as this will help keep the piece cool, reduce the potential of. The present article attempts to experimentally investigate the influence of numerous process variables on machining characteristics in rotary ultrasonic machining of macor ceramic. Macor mgc can be machined with highspeed steel tools, but carbide tools are recommended for longer wear. Achieve the best results by using a water soluble coolant, such as cimstar 40 pink, especially formulated for cutting and grinding glass or ceramics. Assigning numerical values to optimum high speeds and feeds for cutting with ceramics is difficult because of the many process variables that constitute each application. Cutting acrylic 8 guidelines to get the best results. Macor machining guidelines setting up sawing turning milling. Unlike other ceramics, macor can be machined with ordinary metalworking tools. May 30, 2002 macor is a machinable glass ceramic produced by corning.
Ceramics can be made from several different types of hard metal oxides or nitrides. Macor can be machined with high speed steel tools, but carbide tools are recommended for longer wear. The phrases speeds and feeds or feeds and speeds have sometimes been used metaphorically to refer to the execution details of a plan, which only skilled technicians as opposed to designers or managers would know. The starting feed for the best finish is the low rate. Achieve the best results by using a watersoluble coolant, such as cimstar 40 pink especially formulated for cutting and grinding glass or ceramics. But they involve a lot of different concepts, which can make them hard to learn. By grouping machines of similar function, bottlenecks can be anticipated and avoided, allowing work to flow without interruption. Macor machinable glass ceramic offers a potentially lower cost solution to this problem. The starting feed for roughing should be taken from the middle of the feed range.
There is, however, an empirical method of analyzing how close a machining operation using ceramic inserts is to optimum. Macor can be turned, milled, drilled, tapped, sawed and ground by ordinary metalworking tools and techniques. Machinability studies of machinable glassceramic materials. Macor is a machinable glass ceramic produced by corning. Understanding ceramics for jobshop options american machinist. It is machined with highspeed steel or, more easily, with carbide tooling at relatively low speeds and feeds, but with greater depth of cut than is usual with metals. Machining speed and coolant are decisive for successful machining. Macor machinable glass ceramic properties, applications. Machining tolerances are surprisingly tight, up to 10 microns.
This is the first time ive worked on any type of ceramic. Macor can be machined to make precision components but its machining characteristics are different to metals and plastics. Shapal him soft is a hotpressed material available in a variety of billet sizes. Macor machinable ceramic from ceramic products, inc learn. It is a white material that looks somewhat like porcelain. Feeds and speeds are important, because theyre the key to longer tool life, faster machining speeds through higher material removal rates, and better surface finish. Milling speed and feed calculator determine the spindle speed rpm and feed rate ipm for a milling operation, as well as the cut time for a given cut length.
536 970 929 494 926 687 56 259 883 23 447 667 1157 658 1432 1088 888 1464 608 1541 822 159 1039 449 238 1234 1629 343 989 830 656 1235 875 756 1279 681 1356 580 216 678 538 1111 1062 770