Pure Copper Processing Solutions: Precision and Efficiency with NTK’s UC1 and Y-Axis Holder

NTK Cutting Tools (Tungaloy-NTK UK) Tungaloy-NTK UK

Pure copper is widely used across industries, including electronics and automotive, thanks to its excellent conductivity and ductility. However, for machinists and engineers, it also presents a unique set of challenges. Issues such as tool wear, poor chip control, and surface deterioration often arise when working with copper. To meet these demands, NTK offers cutting-edge machining solutions, including the UC1 diamond-coated carbide and Y-axis tool holder paired with high-pressure coolant systems. These tools promise longer tool life, improved chip control, and superior machining precision, particularly when working with small copper parts. In this article, we’ll explore NTK’s solutions and how they can revolutionise copper processing for machinists and engineers in the UK.

Challenges in Pure Copper Machining:

Pure copper, especially grades like C1020 (oxygen-free copper) and C1100 (tough pitch copper), is notoriously difficult to machine due to its softness and high thermal conductivity. Machinists frequently encounter issues such as:

• Tool wear: The softness of copper leads to faster tool wear, requiring frequent tool changes.
• Chip formation: Controlling chip formation is difficult due to copper's ductility. Thick chips can cause clogging, which deteriorates the machined surface.
• Heat dissipation: Copper’s high thermal conductivity can cause excessive heat buildup at the tool’s edge, which further reduces tool life and compromises the surface finish.

Understanding these challenges is critical for selecting the right tools and machining methods to achieve optimal results.

NTK’s Mastery in Pure Copper Processing:

NTK has developed specialized tools to overcome the hurdles in machining pure copper. One of their standout solutions is the UC1 diamond-coated carbide, a tool engineered to provide superior wear resistance and welding resistance, both of which are essential when machining pure copper grades like C1020 and C1100.

The diamond coating on UC1 significantly extends the tool life, making it an excellent choice over traditional PVD-coated carbide tools, which tend to have shorter lifespans. The high purity and hardness of the diamond coating ensure stability, even under challenging machining conditions. Additionally, NTK's expertise extends beyond tool materials to include innovative approaches to chip control, a crucial factor in pure copper processing.

NTK’s Mastery in Pure Copper Processing:

NTK has developed specialized tools to overcome the hurdles in machining pure copper. One of their standout solutions is the UC1 diamond-coated carbide, a tool engineered to provide superior wear resistance and welding resistance, both of which are essential when machining pure copper grades like C1020 and C1100.

The diamond coating on UC1 significantly extends the tool life, making it an excellent choice over traditional PVD-coated carbide tools, which tend to have shorter lifespans. The high purity and hardness of the diamond coating ensure stability, even under challenging machining conditions. Additionally, NTK's expertise extends beyond tool materials to include innovative approaches to chip control, a crucial factor in pure copper processing.

UC1 and Y-axis Holder: The Game Changer for Small Part Machining:

NTK’s UC1 paired with the Y-axis tool holder offers a cutting-edge solution for machining small copper parts. This combination excels in improving precision, extending tool life, and enhancing the surface finish.

• UC1 Diamond-Coated Carbide: With high hardness and excellent adhesion performance, the UC1 delivers long-term stability and wear resistance during copper machining. For example, when machining C1100 tough pitch copper, the UC1 tool can handle up to 1000 pieces per tool corner, compared to just 50 pieces using conventional PVD-coated carbide. This extended tool life is critical in industries such as electronics, where large volumes of precision parts like battery connectors and electrode parts are required.
• Y-axis Holder with High-Pressure Coolant: Combining the UC1 with the Y-axis holder enables better chip control by machining in the Y-axis direction, significantly reducing chip thickness. This approach, when paired with high-pressure coolant systems, ensures efficient heat dissipation and improves surface quality by preventing chip clogging. For copper grades like C1020 and C1100, the Y-axis machining paired with high-pressure coolant helps stabilize chip formation, resulting in smoother, more precise machining operations.

Importance of High-Pressure Coolant in Copper Machining:

High-pressure coolant systems play a pivotal role in pure copper machining, especially when used alongside NTK’s tools. By applying high-pressure coolant, machinists can maintain tool performance while reducing heat buildup, which is a critical concern when working with copper due to its high thermal conductivity.

• Improved Chip Control: High-pressure coolant assists in breaking down chips during high-speed operations, preventing chip clogging that can damage the surface finish. This is particularly important when machining at large depths of cut or high feed rates, as seen in copper machining applications.
• Extended Tool Life: By regulating temperatures more effectively, high-pressure coolant reduces the rate of tool wear. For instance, in machining C1100 electrode parts, using UC1 tools with high-pressure coolant allows for up to 2000 pieces per tool corner, a significant improvement over PVD-coated carbide tools, which manage only 100 pieces per corner.

The combined system of UC1, Y-axis holders, and high-pressure coolant creates a highly efficient machining environment that is ideal for high-precision industries.

Case Studies: Real-World Applications of NTK’s Solutions:

NTK’s machining solutions have already proven successful in a variety of real-world applications. Here are two key examples:

1. Battery Connector – C1100 Tough Pitch Copper Using UC1 DCMT11T302 FNAM3 tools, machinists achieved a cutting speed of 55-110 m/min with a feed rate of 0.03 mm/rev and a depth of cut of 0.2 mm. With wet coolant applied, the tool life reached 1000 pieces per corner, compared to just 50 pieces using a conventional PVD super-coated carbide tool.
2. Electrode Part – C1100 Tough Pitch Copper With the UC1 DCMT11T301 FNAM3, the tool was able to machine 2000 pieces per corner at a cutting speed of 80 m/min, a feed rate of 0.05 mm/rev, and a depth of cut of 1.0 mm, under wet coolant conditions. This performance vastly outstripped the PVD-coated carbide tool, which only managed 100 pieces per corner under the same conditions.

These case studies demonstrate how NTK’s tools significantly extend tool life while improving machining performance.

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.

Boring:

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

The Future of Pure Copper Machining:

NTK’s pure copper processing solutions, particularly the UC1 diamond-coated carbide, Y-axis holders, and high-pressure coolant systems, represent a new era in machining precision and efficiency. By adopting these technologies, machinists and engineers can overcome the challenges of copper machining, reduce tool wear, and improve productivity. For UK machinists working in sectors like electronics and automotive, these tools offer the competitive edge needed to stay ahead in today’s fast-paced industry. As copper machining technology continues to evolve, NTK remains at the forefront, offering innovative solutions to meet the demands of tomorrow.

Interested in learning more?

*View the Full Catalogue here or Contact us Today!