Copper 110, also known as electrolytic tough pitch (ETP) copper, is a popular alloy used in various industries due to its excellent electrical and thermal conductivity, corrosion resistance, and ease of fabrication. In this blog post, we will delve into the world of machining copper 110, discussing the best practices and techniques to achieve optimal results.
Understanding Copper 110
Copper 110 is a highly conductive alloy that contains 99.9% copper and 0.04% oxygen. This alloy is widely used in electrical applications, such as wiring, busbars, and connectors, as well as in heat exchangers and other applications requiring excellent thermal conductivity.
Machining Properties
Copper 110 has excellent machinability, making it a popular choice for a wide range of applications. However, it is essential to use the right techniques and tools to achieve the best results.
#Tooling
Use sharp, high-speed steel (HSS) or carbide tools for machining copper 110. Carbide tools are preferred due to their ability to maintain sharpness and withstand the heat generated during machining. The cutting edge should be honed to a razor-sharp edge to minimize burrs and reduce the cutting force.
#Speeds and Feeds
Copper 110 can be machined at high speeds, but it is crucial to maintain a balance between speed and feed rate to avoid excessive heat buildup. A general guideline is to use cutting speeds of 250-400 surface feet per minute (SFM) for HSS tools and 400-600 SFM for carbide tools. The feed rate should be adjusted according to the tool's size and the depth of cut.
#Lubrication
Using a proper cutting fluid is essential when machining copper 110. A water-soluble oil or a sulfurized oil will help to dissipate heat, reduce friction, and prolong tool life. It is important to apply the cutting fluid directly to the tool and workpiece interface for maximum effectiveness.
#Work Hardening
Copper 110 is susceptible to work hardening, which can lead to a hard, brittle surface that is challenging to machine. To minimize work hardening, use sharp tools, proper cutting speeds and feed rates, and avoid excessive tool pressure.
Machining Techniques
Here are some common machining techniques used for copper 110:
1. Turning: Copper 110 can be turned using a single-point tool with a positive rake angle and a sharp cutting edge. Use proper speeds, feeds, and lubrication to ensure a smooth finish.
2. Milling: When milling copper 110, use a sharp, carbide end mill with a high helix angle to minimize burrs and improve chip evacuation. Climb milling is recommended to reduce work hardening.
3. Drilling: Use a sharp, split-point drill bit with a high helix angle for drilling copper 110. Apply cutting fluid and use appropriate speeds and feeds to prevent work hardening.
4. Tapping: Use a high-quality, sharp tap with a high helix angle for tapping copper 110. Apply cutting fluid and use proper tapping speeds to minimize work hardening and ensure clean threads.
In conclusion, machining copper 110 can be a smooth and efficient process if the right techniques, tools, and cutting conditions are used. Keep these tips in mind to achieve optimal performance and extend the life of your tools while working with this versatile alloy.
