Polished Tungsten Solid Carbide Rod For End Mill

Overview

Polished Tungsten Solid Carbide Rods are premium-grade cylindrical blanks designed for manufacturing high-precision end mills used in demanding applications requiring ultra-smooth surfaces, tight tolerances, and exceptional tool life. These rods are crafted from tungsten carbide (WC-Co) with medium cobalt content (8–12%) and submicron grain sizes (0.6–1μm), balancing hardness (89–92 HRA) with toughness to excel in both ferrous and non-ferrous machining.

The rods undergo a meticulous polishing process to achieve mirror-like surface finishes (Ra ≤0.1μm) and dimensional tolerances within ±0.001mm, ensuring minimal runout and optimal balance in high-speed spindle systems (up to 15,000 RPM). Their superior edge retention and thermal stability make them the material of choice for end mills used in aerospace, medical device, and mold manufacturing industries.

Features

Ultra-Precision Polishing:

Double-sided lapping and centerless grinding to achieve cylindrical accuracy (roundness ≤0.002mm) and surface roughness ideal for high-precision tool holders (e.g., HSK-E32, BT40).

Chamfered ends and radiused edges to prevent stress concentrations during tool assembly, reducing the risk of shank breakage in heavy cuts.

Balanced Mechanical Properties:

Medium cobalt content (10% typical) provides a blend of hardness for wear resistance and toughness to withstand light interrupted cuts, such as slotting in stainless steel.

Submicron grain structure (0.8μm avg.) enhances edge sharpness and resistance to micro-chipping, critical for finishing operations on hardened steels (50–55 HRC).

Thermal & Chemical Resistance:

High melting point (2,870°C) and low thermal expansion enable stable machining at elevated temperatures, with minimal dimensional drift during prolonged cutting.

Compatibility with advanced coatings: PVD-applied TiN, TiCN, or ZrN coatings adhere seamlessly, further enhancing wear resistance and reducing friction.

Consistent Quality Assurance:

100% ultrasonic inspection for internal defects and spectrochemical analysis for alloy composition, ensuring compliance with aerospace standards (AMS 5777, NADCA 207).

Traceability via unique heat lot numbers, enabling full material history tracking from powder to finished rod.

Applications

Aerospace Component Machining: End mills for titanium alloy (Ti-6Al-4V) wing ribs and inconel 718 turbine casings, where tool life and surface finish (Ra ≤0.8μm) are critical for structural integrity.

Medical Device Manufacturing: Micro-end mills for machining cobalt-chromium orthopedic implants and zirconia dental crowns, requiring micron-level precision for press-fit interfaces and osseointegration surfaces.

Mold & Die Making: Finishing end mills for hardened steel molds (52 HRC) used in plastic injection molding, achieving mirror finishes (Ra ≤0.2μm) without secondary polishing.

Precision Instrumentation: End mills for machining brass and stainless steel components in watches and optical devices, where dimensional accuracy within ±5μm is essential for functional fit.

FAQ

Q: What is the difference between polished and ground carbide rods?

A: Polished rods have a smoother surface (Ra ≤0.1μm) and tighter roundness tolerances (≤0.002mm), ideal for high-precision end mills. Ground rods (Ra ≤0.2μm) are suitable for general-purpose tools.

Q: Can these rods be used for roughing operations?

A: While they excel in finishing, medium cobalt grades can handle light roughing in steels up to 45 HRC. For heavy roughing, consider higher cobalt grades (15% Co) for increased toughness.

Q: How does the polishing process affect rod performance?

A: Polishing reduces surface defects and friction, improving coolant flow and chip evacuation. It also enhances the bond strength of PVD coatings, leading to longer tool life.

Q: Do you offer custom rod lengths for special end mill designs?

A: Yes, we provide custom lengths from 50mm to 1,500mm, with special processing for stepped or tapered shanks to meet unique tool geometries.