The Advantages of Carbide Tipped Tools

compiled and edited by​ Bernard Martin

The choice between various materials can significantly impact performance, productivity, and cost-effectiveness in Metalcutting manufacturing. Among the materials commonly used for cutting tools, carbide-tipped tools have remained in prominence for their remarkable advantages when compared to solid carbide and high-speed steel (HSS) tools. In this article, based upon information supplied by Hannibal Carbide, we explore the distinctive benefits of carbide-tipped tools by comparing them to their solid carbide and HSS counterparts.

Durability and Longevity
One of the foremost advantages of carbide-tipped tools is their exceptional durability and longevity. These tools combine the best of both worlds, featuring a tough steel body with a carbide insert at the cutting edge. When compared to solid carbide tools, carbide-tipped tools often outlast them due to their ability to withstand high-impact applications. In contrast, HSS tools are more prone to wear and require frequent regrinding or replacement

Versatility​
​Carbide-tipped tools offer a remarkable level of versatility. The carbide inserts are available in various grades, each tailored to specific machining tasks. This adaptability allows users to choose the ideal carbide grade for their application, optimizing tool life and performance. In contrast, solid carbide tools, while highly capable in specific applications, lack the flexibility to adapt to various materials and machining conditions. HSS tools, though versatile, may not match the cutting speed and precision of carbide-tipped tools in demanding applications.

Cutting Speed and Efficiency
Carbide-tipped tools excel in cutting speed and efficiency, making them a preferred choice for high-production environments. The hardness of carbide allows for faster cutting speeds, which translates to reduced machining time and increased productivity. Solid carbide tools come close but may not always match the speed and efficiency of carbide-tipped tools, especially when it comes to demanding materials like stainless steel or hardened alloys. HSS tools, on the other hand, are often outpaced in terms of cutting speed and efficiency.

Heat Resistance
Heat resistance is a critical factor in machining, especially when working with materials that generate high temperatures during cutting. Carbide-tipped tools have superior heat resistance compared to HSS tools. The carbide can endure high temperatures without losing its cutting edge, ensuring consistent performance even under demanding conditions. Solid carbide tools have good heat resistance but may be prone to chipping or breakage when subjected to extreme heat, which is less of an issue for carbide-tipped tools.

Cost-Effectiveness
While the initial cost of carbide-tipped tools may be higher than HSS tools, their durability and longevity make them a cost-effective choice in the long run. Solid carbide tools, while durable, can be more expensive and may not justify their cost in all applications. HSS tools, although cheaper initially, may need more frequent replacements and regrinding, ultimately incurring higher costs over time.

In the world of cutting tools, carbide-tipped tools stand out as a versatile, high-performance, and cost-effective solution. Their unique combination of a tough steel body with a carbide insert at the cutting edge offers durability, versatility, high cutting speeds, heat resistance, and cost savings. While solid carbide and high-speed steel tools have their merits in specific applications, carbide-tipped tools are the go-to choice for industries and machinists looking to maximize efficiency and quality across a wide range of machining tasks. Whether you're working with metals, plastics, or composites, carbide-tipped tools provide a winning edge in the world of precision cutting and machining.

Advantages of Carbide Tipped
vs.
​High Speed Steel

• Higher feeds & speeds
• Retains cutting edge at very high machining temperature
• More aggressive machining reduces cycle time
• Exceptional wear resistance at cutting edge
• Holds size far longer (see lower right graph)
• Far longer runs before resharpening
• Reduces machine downtime for tool changes
• Chip forming surface resists wear much better
• Cratering minimized

Advantages of CARBIDE TIPPED
VS.
​SOLID CARBIDE ADVANTAGE

Cracked solid carbide tool shatters

• Carbide grade selected for cutting characteristics - not compromised for structural strength
• Tipped tools usually cost less than solid carbide
• Often utilize specialty carbides not available in solid round forms
• Expensive carbide only used for cutting edge & chip forming surface
• More aggressive cutting edge geometries - shear, edge & rake angles
• A shattered solid carbide tool often damages the piece being machined
• Hardened tough alloy steel body provides superior structure to absorb shock loads
• Carbide cracks stopped in steel body pocket rather than shattering the entire tool
• Reduced scrap & machine downtime as even a cracked carbide tipped tool keeps cutting
• Carbide cracks stopped in steel body pocket rather than shattering the entire tool

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​ADVANTAGEs of CARBIDE TIPPED
​VS.
CARBIDE INSERT

Cracked carbide tipped tool keeps cutting

• Initial tooling costs far lower for carbide tipped tools
  
• Insert pocket interferes with chip flow
• Vibration-free brazed carbide tip permits higher feeds & speeds since inserts simply cannot be securely clamped to avoid all vibration problems
• Far better finish using carbide tipped tools

• Inserts are impractical for many operations such as reaming and most drilling

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