In the field of metal processing, saw blades and milling cutters are key tools for cutting and grooving, and the choice of materials directly determines the processing efficiency, precision and cost. As the two mainstream substrates, high-speed steel (HSS) and cemented carbide (tungsten steel) show significant differences in performance. This article deeply analyzes the differences between the two from four dimensions: material properties, applicable scenarios, cost structure and processing precision, providing a scientific basis for your tool selection.
1. Comparison of material composition and core characteristics
1.1.High-speed steel saw blade milling cutter is based on high-carbon high-alloy steel, mainly containing tungsten (W), molybdenum (Mo), chromium (Cr), vanadium (V) and other elements. Some high-performance models add cobalt (Co) to enhance performance. For example: HSS 8% cobalt: excellent heat resistance, can withstand higher cutting temperatures Ordinary HSS: hardness of about HRC64-68, excellent toughness but limited wear resistance Its advantages are high toughness and impact resistance, and it is not easy to break the blade under intermittent cutting or vibration conditions, but the upper limit of red hardness is about 600℃, and the hardness decays rapidly at high temperatures47.
1.2.Carbide saw blade milling cutter (tungsten steel) is made of micron-sized powders of metal carbides such as tungsten carbide (WC) and titanium carbide (TiC) and cobalt binder sintered at high temperature and high pressure. According to the grain size, it is divided into: Microcrystalline carbide (0.2-2μm): strong and impact-resistant, suitable for heavy-duty intermittent cutting Ultrafine/nano carbide (<0.5μm): extremely high hardness, wear resistance increased by more than 50%, suitable for precision machining Its core advantages are ultra-high hardness (HRA86-93, equivalent to HRC75-80) and red hardness (900-1000℃ does not soften), but it is brittle and its bending strength is only 1/3-1/2 of that of high-speed steel.
2. Significant differences in applicable scenarios
2.1. High-speed steel saw blade: economical soft material processing solution Typical materials
non-metals such as aluminum, brass, low-carbon steel, plastic and wood Applicable working conditions: Manual machine tools or low-rigidity equipment (such as old milling machines, drilling and milling equipment) Scenarios where cutting conditions are unstable and vibration is easy to occur Small batch and multi-variety processing requires strong tool versatility.
Performance limitations: When processing high-hardness materials such as stainless steel and titanium alloy, the cutting edge wears rapidly, and the life is less than 1/5 of that of cemented carbide.
2.2. Cemented carbide saw blade: the first choice for efficient hard materials and precision processing Typical materials
stainless steel (such as 316/317), heat-resistant steel, titanium alloy, hardened steel, composite materials Advantage scenarios: CNC machine tools, high-rigidity machining centers High-speed cutting (linear speed can reach 4-7 times that of high-speed steel) Batch continuous processing requires long tool life and high dimensional stability .
Special value: Ultra-thin design (thinnest 0.2mm) saves precious materials and is suitable for cutting gold and ceramic-based composite materials.
3. Cost structure and economic benefit analysis
3.1Initial purchase cost
3.1 .1High-speed steel saw blade: The price is only 1/3-1/2 of that of cemented carbide, especially the small diameter model (<50mm) has a significant cost advantage.
3.1.2Cemented carbide saw blade: Because tungsten carbide and cobalt raw materials are expensive and the process is complicated, the unit price is 2-3 times higher.
3.2. Long-term use cost
3.2.1 Life cycle: Cemented carbide has excellent wear resistance, and its life can reach 5-80 times that of high-speed steel under the same processing conditions57 Grinding cost: High-speed steel is easy to grind and can be repaired by ordinary grinding machines, but the frequency is high (grinding is required every 2-4 hours of processing).
3.2.2 Cemented carbide requires special diamond grinding wheels for grinding, with high single cost but long intervals (continuous processing for 8-24 hours) Comprehensive benefits: When processing stainless steel in batches, although the unit price of cemented carbide is high, the unit cost can be reduced by more than 40% due to improved efficiency and reduced tool change downtime.
4. Differences in machining accuracy and process requirements
4.1. Dimensional accuracy and surface quality
4.1.1 High-speed steel saw blade: The initial sharpness of the blade is excellent, but it wears quickly and the dimensional accuracy gradually decreases during machining It is easy to obtain a surface roughness of Ra1.6-3.2μm when cutting soft materials, but it is easy to produce burrs when machining hard materials
4.1.2 Carbide saw blade: High rigidity keeps the blade shape stable, and the machining tolerance can be controlled within ±0.02mm During high-speed cutting, the workpiece temperature is low, the thermal deformation is small, and the surface roughness can reach Ra0.4-0.8μm (especially ultra-fine grain models).
4.2. Key points of process control
4.2.1 High-speed steel: Adjust the feed rate based on operator experience to avoid overload (recommended feed rate per tooth 0.03-0.1mm/tooth).
4.2.2 Cemented carbide: Requires precise matching of speed/feed rate (recommended feed rate per tooth 0.005-0.025mm/tooth). Must clamp with high rigidity, slight vibration will lead to chipping. Recommend oil mist cooling or minimal lubrication (MQL), avoid thermal shock of water-based coolant.
If you have procurement needs for saw blade milling cutters, please contact us. Changzhou Zhiyu Carbide Tools is a high-quality manufacturer of saw blade milling cutters.
