Pure Copper Processing SolutionsFor turning small parts ｜ UC1 and Y axis holder + High-pressure coolant

The Master of Pure Copper Processing
The search for an answer led me to NTK

NTK's Work Changing Concept

Diamond-coated carbide : Longer tool life with UC1
Improved chip control with Y-axis tool holder + high-pressure coolant

Performance

  • High purity, high hardness diamond coating, and excellent adhesion performance enable long-term stable machining
  • Improved chip control by applying Y-axis direction machining with high-pressure coolant

Applications

Pure copper (C1020/C1100) machined using Sliding head automatic lathes or CNC-lathes

Diamond-coated carbide：UC1

〔 Machining Property of C1100 Tough Pitch Copper 〕

Diamond-coated carbide: UC1 with excellent wear resistance & welding resistance is recommended because tooling tends to wear and the machined surface deteriorates due to welding, resulting in short tool life.
A good machined surface can be obtained by applying the appropriate cutting condition (low cutting depth/low feed) which reduces the chip thickness.

Case Study

Battery connector
Material
 C1100 φ.394 -.787 in.
Speed
(SFM)
 180 - 360
Feed
(IPR)
 .0012
DOC
(inch)
 .008
Coolant
 WET
UC1 DCMT32.508 FNAM3

1000 pcs / corner
PVD super coat DCGT32.508 molded chipbreaker

50 pcs / corner

Electrode part
Material
 C1100 φ.472 in.
Speed
(SFM)
 262
Feed
 (IPR)
 .002
DOC
(inch)
 .040
Coolant
 WET
UC1 DCMT32.504 FNAM3

2000 pcs / corner

PVD super coat DCGT32.504 molded chipbreaker

100 pcs / corner

Machined Surface Comparison

[ Cutting conditions ]
Part material : C1100 vc=260 SFM ap=.040 WET
[ Tools used ]
DCMT32.508FNAM3 UC1

If the cutting conditions cause the chips to become thick (high cutting depth or high feed) then the machined surface will deteriorate due to chip clogging.

Cutting conditions

Scroll the table →

Grade Tool Operation Machining Speed (SFM) Feed (IPR) DOC (inch) WET
UC1 Tough pitch copper C1100 Turning Rough - Finish 160 - 500 .0008 - .002 .008 - .080 ●

Using the cutting conditions shown, chips can be segmented and controlled with AM3 chipbreaker.
When machining at large depths of cut and high feed rate, select CL or ZP chipbreakers to suppress chip clogging.

〔 Machining Properties of C1020 Oxygen-free Copper 〕

Stable chip generation may be difficult with a chip breaker alone, it is recommended to add a Y-axis holder + high pressure coolant

Scroll the table →

Cutting Conditions

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Grade Tool Operation Machining Speed (SFM) Feed (IPR) DOC (inch) WET
UC1　TM4 Oxygen-free copper C1020 Turning Rough - Finish 160 - 500 .0008 - .008 .020 - .118 ●

Refer to content above to select cutting conditions and chip breaker to obtain good chip control.
If you want longer tool life than PVD Carbide: TM4, use Diamond-Coated Carbide: UC1.

〔 Boring 〕

Improve chip control by using FG/F1 chip breakers to evacuates chips backwards and high-pressure coolant

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Cutting conditions

Scroll the table →

Grade Tool Operation Machining Speed (SFM) Feed (IPR) DOC (inch) WET
UC1　TM4 C1100　C1020 Turning Finish 160 - 500 .0008 - .002 .004 - .020 ●

If you want longer tool life than PVD Carbide: TM4, use Diamond-Coated Carbide: UC1.

Insert lineup

Scroll the table →

●: Stock
○: 1-2 week delivery
Shape EDP Item Number Corner R Grade Dimensions (inch)
UC1 TM4 IC Thickness
AM3 2 corners available 5970728 DCMT 32.504 FN AM3 .004 ● 3/8 5/32
5970736 32.508 FN AM3 .008 ●
5970744 32.51 FNA AM3 .016 ●
F1 ※ 3 corners available 5970702 TPMH 2208 FR F1 .008 ○ 1/4 1/8
5970710 221 FR F1 .016 ○
ZP 6 corners available 5970686 TNMG 3308 FN ZP .008 ● 3/8 3/16
5967351 331 FN ZP .016 ●
5970694 332 FN ZP .031 ●
ZP 4 corners available 5970660 CNMG 431 FN ZP .015 ● 1/2 3/16
5970678 432 FN ZP .031 ●
AM3 5694633 DCGT 32.504M FN AM3 .003 ○ 3/8 5/32
5694641 32.508M FN AM3 .007 ○
5693783 32.51M FN AM3 .015 ○
CL※2 5757091 DCGT 32.504M CL .003 ● 3/8 5/32
5758040 32.508M CL .007 ●
5765730 32.51M CL .015 ●
FG※ R-hand shown 5790100 TPGP 7308 R FG .008 ● 7/32 3/32
5790092 731 R FG .016 ●
5790142 TPGH 2208 R FG .008 ● 1/4 1/8
5790134 221 R FG .016 ●
ZP 5731146 TNGG 3308 FN ZP .008 ○ 3/8 3/16
5731211 331 FN ZP .016 ○

* The R symbol (01M,02M,04M,08M) can be used for machining where the R indication of the workpiece part is less than or equal to R0.1,R0.2,R0.4,R0.8.
* Right-hand inserts with FG and F1 chipbreakers should be used with right-hand holders
*2 The CL breaker differs slightly from the above dimensions due to product specifications, but there is no problem with machining.

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