How to Cut Carbide Rods Effectively and Improve Chip Evacuation?

In the field of metal processing, tungsten carbide rods are renowned for their extremely high hardness, strong wear resistance and excellent anti-deformation ability. It is almost one of the hardest materials after diamond, and thus is widely used in the manufacture of drill bits, end mills, stamping dies and various high-precision cutting tools. However, this advantage also brings a problem – it is too hard, and traditional cutting equipment is often at a loss. How can one cut smoothly without damaging the material? Then, how can efficient chip evacuation be achieved during cutting? This article will reveal the core points of tungsten carbide rod processing from principles, methods to practice for you.

The Structure And Application Of Tungsten Carbide Rods

Tungsten carbide is a kind of hard alloy material, usually made by sintering tungsten powder and carbides at high temperature and high pressure. Its hardness can reach over HRA90, approaching that of diamond, but it is relatively brittle, which means it is “hard but not tough”.

During the cutting process, any improper pressure, temperature or vibration may cause surface chipping or internal microcracks. Therefore, many processors will find that when cutting tungsten carbide rods, the cutting tools wear out extremely fast, the cut edges turn black, and even the material may be burned.

Tungsten carbide rods can be classified into solid carbide rods and coolant Hole rods according to different processes.

• Solid Carbide Rod is often used to manufacture end mills, drill bits and forming tools. 
• Coolant Hole Rod is equipped with cooling holes inside, which are used to discharge coolant and chips during high-temperature processing.

In addition, the surface of tungsten carbide rods is divided into two types: Ground rods and Unground rods. The former has a smooth surface and high precision. The latter is more suitable for subsequent reprocessing.

Tungsten carbide rods of different specifications and structures have different requirements for cutting methods and tools.

How to Cut Tungsten Carbide Rods?

The correct cutting method determines the processing quality and cost control. The following are several common methods and their applicable scenarios:

1. Common cutting methods

Cutting Method	Features	Advantages	Suitable Applications
Diamond Wheel Cutting	Uses diamond abrasive wheel for grinding and cutting	High precision, smooth cutting surface	Small-batch production, precision machining
EDM (Electrical Discharge Machining)	Removes material through electrical discharge	No mechanical stress, suitable for complex shapes	Molds, dies, or special-shaped components
Laser Cutting	Uses high-energy laser beam to melt material	Fast cutting speed, contact-free process	Thin parts, micro components
Waterjet Cutting	Employs high-pressure water mixed with abrasive particles	No heat-affected zone, clean surface finish	Heat-sensitive materials or surface-quality applications

In actual production, diamond grinding wheel cutting is the most common. It can achieve high-speed and high-precision cutting while maintaining the smoothness of the cut. For products with complex shapes or high precision requirements, EDM electrical discharge machining has more advantages.

2. Operating skills and precautions

• Maintain cooling: Tungsten carbide conducts heat slowly and is prone to overheating during cutting. It should be used in conjunction with a coolant or air cooling system.
• Reasonable control of speed and pressure: Too fast feed will cause chipping, while too slow will reduce efficiency.
• Choose high-quality cutting tools: Use diamond or cubic boron nitride (CBN) tools, which are sharp and wear-resistant.
• Avoid vibration: The machine must be stable to prevent cracks caused by micro-vibrations.
• Take proper precautions: The dust generated during cutting contains tungsten, so a ventilation device and a protective mask should be provided.

Cutting Suggestions for Cemented Carbide Rods

Although tungsten carbide rods and cemented carbide rods are often used interchangeably, there are still subtle differences in their cutting processes.

• For small-diameter bars, it is recommended to adopt segmented cutting to avoid fracture caused by thermal stress.
• For long rods or large-diameter materials, multi-point support and slow feed should be used to maintain straightness.

After cutting, the bars usually still need to undergo chamfering, trimming and polishing to ensure a smooth surface and relieve stress.

How Solid Carbide Rod Optimize Chip Evacuation During Cutting?

Many people only focus on the cutting speed but neglect the crucial step of chip evacuation. During the cutting process, if the chips cannot be removed in time, it will not only affect the surface quality, but also cause tool blockage, temperature rise, and even lead to the scrapping of the workpiece.

1. The importance of chip evacuation

Chip evacuation is like a respiratory system – smooth chip evacuation channels can help the processing area dissipate heat quickly and prevent chip accumulation. On the contrary, poor chip evacuation is like a clogged pipe, which will make the cutting process difficult and rough.

2. Optimize the structural design of chip evacuation

High-quality solid tungsten carbide rods have been optimized for chip evacuation through structural design during the production stage:

• Flute design: a reasonable channel shape can guide debris out and reduce friction.
• Internal cooling holes: During high-speed cutting, coolant is transported through the internal cooling structure, effectively removing heat.
• Surface finishing treatment: The ground bars reduce cutting resistance, making the processing smoother.

These designs not only reduce tool wear but also extend cutting life and enhance overall efficiency.

3. Practical application effect

In the manufacturing of drill bits, end mills and thread tools, the use of high-quality solid tungsten carbide rods can make the cutting more stable.

For instance, in the processing of stainless steel or titanium alloys, a good chip evacuation system can significantly reduce the cutting temperature, prevent tool chipping, and make the entire production process smoother.

Final Words

Cutting tungsten carbide rods may seem difficult, but in fact, as long as the correct equipment, parameters and cooling methods are mastered, it can be easily accomplished. The key lies in understanding the material properties, choosing the appropriate cutting method, and taking into account chip evacuation and temperature control during processing. High-quality solid tungsten carbide rods not only enhance processing accuracy but also maintain stable chip evacuation and heat dissipation performance during cutting.

If you are looking for tungsten carbide rods with stable performance, precise size and excellent chip evacuation design, XYMJ’s solid tungsten carbide rods will be your ideal choice. It can provide reliable support in high-intensity cutting, helping you achieve a more efficient and smoother metal processing experience.

FAQ

Q1: Can a regular cutting machine be used?

Not recommended. The hardness of tungsten carbide far exceeds that of ordinary steel. Ordinary cutting discs cannot cut through it and may even damage equipment. It is recommended to use dedicated diamond grinding wheels or electrical discharge cutting equipment.

Q2: What should I do if cracks appear after cutting?

Cracks are usually caused by insufficient cooling or excessive pressure. The feed rate should be reduced and the cooling effect enhanced.

Q3: What consequences will there be if chip evacuation is not smooth?

Poor chip evacuation can lead to overheating of the cutting tool, scratches on the workpiece surface, and even cracking. You can check whether the tool groove is blocked or whether the cooling system is normal.

Q4: How to extend the service life of cutting tools?

Keeping tungsten carbide rods sharp, using high-quality materials, and regularly cleaning and replacing worn parts are the keys to maintaining efficient processing.

Related Products