One of the best materials for machining is brass. Brass is a metal alloy composed of copper and zinc. It is used widely in many industries worldwide but underutilized in the US. Using the right machining tools for brass can improve the material removal rate and extend the cutting tools’ life. Using spindle liners can also protect the workpiece and equipment. By reducing the clearance between the workpiece and tool, you can increase machining speed and improve quality.
Alloy C3600
Brass is one of the most common materials used in machining. Its machinability is excellent and it’s the preferred material for a wide variety of applications. It’s also corrosion-resistant and possesses moderate strength. In addition, brass is easy to work and solders well.
C3600 Brass has a lead content of 2.5% to 3.7% and is an excellent choice for free-cutting and machining applications. Its machinability rating is 100, which makes it ideal for high-speed machining. This alloy has excellent brazing properties and is a good substitute for leaded steel.
When considering materials for machining, be sure to consult the ISO Machinability Test. The ISO-certified test involves a reference work piece, reference tool materials, and reference cutting fluids. In addition, the method includes measuring tool wear and evaluating tool life. The table below shows the tensile requirements of a piece of Alloy C3600 alloy. It also covers the economics of turning operations.
Another common alloy to be machined is Ti. This metal has a hardness of 59.4 HRA and is made from Ti6Al4V. Its machining requires high forces and requires high cutting speeds. The cutting process will also affect the feed and depth of the cut, which need to be re-optimized.
Free Cutting Brass
Free cutting brass machining is a method of creating a high quality brass part without using any lead. This type of brass alloy is called Ben Fa Ming ha. It has excellent machinability, hot workability, and erosion/corrosion resistance. It is comprised of a Zn content of 19 to 22.0 wt%, Si content of 2.0 to 3.5 wt%, and Pb content of 0.20 wt%.
The process of free cutting brass machining is performed in a lathe after cutting the brass bars with a power saw. Afterwards, the metal is subjected to heat treatment at 550 to 600 degrees Celsius for a period of one to twelve hours. This process allows the material to achieve an 80% phase proportion.
Free cutting brass machining requires very little maintenance and can be a great way to reduce overall costs. It is also a very environmentally friendly way to produce brass components. The brass scraps produced by this process can be recycled and melted down into new brass products. This process also saves landfill space as no brass is disposed of.
The minimum wall thickness achievable for free cutting brass machining is 0.03″ although this number may vary depending on the planar dimension and the type of brass used. Copper C260, a zinc alloyed formulation, is often referred to as cartridge brass, and is commonly used in the fabrication of radiator cores, hinges, and rivets. Meanwhile, Copper C360, also known as free cutting brass, is highly machinable and suited for screw and gear machine parts.
Free cutting brass is an alloy that can be forged, hammered, and soldered. As a result, it is a versatile material that is highly resistant to corrosion. Further, it is easy to machine. Its high strength makes it an excellent choice for fast production. Its high machinability also means that it is a cost-effective material.
Optimum machining parameters include feed rate, depth of cut, and surface roughness. These variables are correlated and determine the optimal turning conditions. These parameters are essential in free-cutting brass machining. If you want to make a precise product, you have to manipulate the parameters in the system. Fortunately, a technique called Response Surface Methodology can provide a solution for this problem. It uses mathematical algorithms to analyze and select the optimal measuring parameters.
When you want to manufacture a brass part with the minimum number of setups, free cutting brass machining is an ideal choice. Brass is a dense, low-friction metal that readily accepts machining. Besides, the resultant brass surface is very attractive. Additional finishing passes are also recommended to further improve the finish of the brass part.
