Copper alloy 110, also known as electrolytic tough pitch (ETP) copper, is a popular material due to its high electrical and thermal conductivity, excellent ductility, and ease of fabrication. As a result, it is widely used in the electrical industry, heat exchangers, and various mechanical applications. Machining copper alloy 110 can be challenging due to its softness and high ductility, which can lead to built-up edges, tool wear, and poor surface finish. In this blog post, we will discuss the tips and techniques for effectively machining copper alloy 110 to ensure optimal performance and high-quality results.
Material Properties of Copper Alloy 110
Before diving into the machining tips, it is essential to understand the material properties of copper alloy 110. This alloy consists of 99.9% copper, with trace amounts of oxygen and other impurities. It has a tensile strength of 32,000 psi and a yield strength of 10,000 psi, making it relatively soft compared to other metals. The material's high thermal conductivity means that heat generated during machining is quickly dissipated, which can be both an advantage and a challenge.
Tool Selection for Machining Copper Alloy 110
Choosing the right tool is critical for achieving the desired results when machining copper alloy 110. The following factors should be considered when selecting tools:
1. Tool Material:Carbide tools are recommended for machining copper alloy 110 due to their high wear resistance and ability to maintain a sharp cutting edge. High-speed steel (HSS) tools can also be used, but they tend to wear more quickly and require more frequent sharpening.
2. Tool Geometry:Sharp cutting edges and large rake angles are essential for preventing built-up edges and ensuring a smooth surface finish. A positive rake angle of 10-20 degrees is recommended for turning operations, while a rake angle of 5-15 degrees is suggested for milling.
3. Tool Coating:Although not always necessary, coatings such as titanium nitride (TiN) or diamond-like carbon (DLC) can improve tool life and performance when machining copper alloy 110.
Machining Parameters for Copper Alloy 110
Proper machining parameters are essential for achieving the desired results when working with copper alloy 110. The following guidelines can help:
1. Cutting Speed:Due to its high thermal conductivity, copper alloy 110 can be machined at relatively high cutting speeds. Recommended cutting speeds for turning operations range from 250-500 feet per minute (fpm), while milling speeds can be between 300-600 fpm.
2. Feed Rate:A high feed rate is essential for preventing built-up edges and ensuring a smooth surface finish. Recommended feed rates for turning operations range from 0.008-0.015 inches per revolution (ipr), while milling feed rates can be between 0.002-0.006 inches per tooth (ipt).
3. Depth of Cut:A shallow depth of cut can help prevent built-up edges and reduce tool wear. Recommended depths of cut for turning operations range from 0.030-0.060 inches, while milling depths can be between 0.010-0.030 inches.
Lubrication and Cooling for Machining Copper Alloy 110
Proper lubrication and cooling are essential for achieving the desired results when machining copper alloy 110. The following guidelines can help:
1. Coolant:A water-soluble coolant is recommended for machining copper alloy 110, as it provides excellent heat dissipation and lubrication. A coolant concentration of 5-10% is typically sufficient for most operations.
2. Coolant Application:Flood coolant or high-pressure coolant systems can be used to ensure adequate heat dissipation and lubrication during machining. Proper coolant application can also help prevent built-up edges and extend tool life.
3. Air Blowing:In some cases, air blowing can be used in conjunction with coolant to help remove chips and prevent built-up edges. However, care should be taken to avoid excessive air pressure, which can cause chip adhesion and poor surface finish.
Workholding and Fixturing for Copper Alloy 110
Due to its softness and high ductility, copper alloy 110 can be challenging to hold securely during machining operations. The following tips can help ensure proper workholding and fixturing:
1. Clamping Pressure:Care should be taken to avoid excessive clamping pressure, which can cause distortion and damage to the workpiece. Soft jaws or copper
