Mill Tooling

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CNC milling tool for machining bonded sand?

I need a tool enough hard to machine a sand material that is chemically bonded. Carbides are not enough hard. I cannot use coolant.

This is a bit of a toughie.

I would say use a harder grade of carbide - and/or a micrograin type.

If you don't know mutch about carbide tools, then now is as good a time to learn. There are many different grades. Carbide tools use tungsten carbide embedded in a cobalt matrix which hold all the particles together. The ratios are varied - to give either harder tips - that are likely to shatter, or tougher tips - which are more likely to blunt.

If you are cutting an abrasive material, Then pick a tool with replacable industry standard tips, Run your speeds about half what is recommended, and up your feedrate to about 75% of what you would normally use. Use a larger tool if possible - then finish with a fine.

Use compressed air or mist system foor cooling the tool.

If it's overheating - just slow down everything.

If you know anything about CNC's - you will know that there is the manufacturers "optimim" feeds and speeds, and then there is those that actually work, due to workholding/ rigidity issues and the playoff of productivity vs tool life.

Carbide tools are also available coated with Titanium nitride or tungsten nitride, or can be bonded onto HSCO tool shanks for flexibility - and thus higher feed rates (I've actually used 6mm bonded end mills that bend about 15 degrees during high feedrates - and look impossible!)

Good luck with that.
(who decided bonded sand ? - what's the advantage there?)

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