Scarfing Insert Blanks
Product Type: Scarfing Insert Blanks
Description: Customized, preformed inserts made of tungsten carbide and cermet designed for the production of scarfing tools.
Hyperion engineers designed customized insert blanks specialized for top-tier scarfing tools to overcome the challenges of extreme temperatures and abrasive materials.
Carbide insert blanks for scarfing tools help toolmakers develop inserts that efficiently remove excess material from the OD and ID of tubes and pipes. Developed with tight tolerances, Hyperion’s insert blanks improve the consistency and precision of inserts when scraping or cutting away excess metal.
Toolmakers can count on customized insert blanks to significantly reduce the processing time of complex scarfing inserts. Leveraging preformed inserts allows toolmakers to maximize productivity by spending less time shaping complex profiles. Preformed inserts reduce grinding steps, so toolmakers can spend less time on contour grinding, edge preparation, and surface finishing.
Challenges of Machining Inserts for Scarfing Tools
Scarfing tools are specialized cutting tools that remove surface defects and excess material around welding seams. Primarily used in metal pipe and tube manufacturing, scarfing tools ensure quality and consistency of the joining of pipes and tubes.
Scarfing tools face challenging conditions in high-speed, high-precision metalworking environments, impacting tool performance and longevity.
- Extreme Temperatures - During weld bead removal, scarfing tools continuously generate intense heat, leading to insert wear, thermal cracking, and ultimately reduced tool life.
- Very Hard and Abrasive Materials – Oxides generated from welding parts and tubes leads to abrasive conditions for inserts, accelerating wear on the cutting edge. As wear is more noticeable on the cutting tool, end users require frequent tool replacement or regrinding, leading to operational unproductivity and higher costs.
- Maintaining Precision – Scarfing requires consistent, tight tolerances on both the OD and ID. Without it, there will be flaws within pipes and tubes.
Carbide Grade MP40 for Scarfing Tools
Toolmakers aim to minimize machining time when developing tooling for scarfing applications, while maintaining a high-level of tool performance under demanding conditions. Hyperion’s tungsten carbide grade MP40 delivers exceptional productivity. MP40 is a premium carbide grade offering an optimal balance of hardness, toughness, and wear resistance at very high temperatures, to reduce wear and tear on the cutting edge during aggressive material removal.
Critical in the metal-removal process, carbide grade MP40 enhances the insert’s structural integrity and surface finish to provide substantial tool longevity. MP40 delivers excellent corrosion resistance and minimizes galling during weld bead removal in tubular applications. With a well-balanced combination of hardness and wear resistance, MP40 insert blanks maintain edge integrity under extreme temperatures.
Improved structural integrity ensures inserts maintain sharpness for a more stable cutting edge. The stability of the edge leads to a cleaner and smoother cut. As a result, scarfing rings and inserts effectively remove surface defects and prepare welded metal sheets and pipes for downstream processing, meaning there is less need for post-processing in scarfing, saving end-user time and costs.
Toolmakers who leverage carbide grade MP40 minimize the risk of the insert and ring chipping or breaking during rapid temperature changes and high-impact machining. MP40 helps tools resist thermal shock and wear-induced stress cracks, enduring the abrasive conditions of scarfing without significant degradation.
By utilizing grade MP40, toolmakers deliver higher output tooling by minimizing cohesion and preventing tool damage during scarfing operations on tubes, stainless steel and steel alloys. MP40 enables consistent and reliable scarfing tooling that delivers uniformity in dimensions and quality. Toolmakers produce tools faster with fewer failures for end users.
Carbide grade MP40 enhances an insert’s durability, leading to longer-lasting performance, fewer replacements, and consistent cutting performance over extended use. Toolmakers can count on producing tools that allow users to experience less downtime for more predictable machining operations.
Blanks for OD and ID Scarfing Inserts
Hyperion offers custom insert and ring blanks for OD and ID scarfing. Insert blanks serve as the foundational material from which the final scarfing insert is shaped and customized. OD scarfing insert blanks are developed to withstand high rotational forces and maintain consistent cutting geometries across varying tube sizes and materials.
ID scarfing insert blanks can be precisely configured with tight tolerances to machine specific areas. Using high-quality insert blanks ensures final inserts deliver optimal performance, resist wear, and maintain cutting efficiency over extended production runs.
Scarfing Tool Insert Applications
There are three primary types of scarfing tool inserts: scarfing rings, scarfing inserts, and roughing inserts. Each insert type serves a distinct role in the scarfing operation to prepare tubes and pipes for further processing.
Scarfing Rings
Scarfing rings are used for internal weld bead removal (ID scarfing). Mounted inside the tube, these circular tools rotate and shave off the internal weld seam. Used in tube scarfing, scarfing rings allow for precise cutting within confined spaces and are typically made of carbide to withstand high temperatures and friction.
Scarfing Inserts
Mounted on scarfing heads, scarfing inserts engage the outer surface of the tube to remove the weld bead formed during the welding process. Often designed as indexable, OD scarfing inserts allow for quick replacement and reduced downtime in production.
Roughing Inserts
Roughing inserts are used in the initial stages of scarfing to remove bulk material of weld beads or excess surface material. Designed for aggressive cutting and material removal, roughing inserts prepare the surface for finishing operations and are appropriate for thicker welds or harder materials.
Contact a local Hyperion sales representative for more details on enhancing scarfing tool performance in high-speed machining.
