Regrinding Inserts

Be Kind, Regrind: 

The Benefits of Regrinding Your Carbide Inserts

In the realm of metal cutting and machining, regrinding carbide drills and end mills is a common practice that offers significant cost savings and supports sustainability goals. However, when it comes to carbide inserts, the regrinding programs are not as widespread. Traditionally considered disposable, some carbide inserts can actually be reground, provided certain conditions and best practices are followed. Here’s a comprehensive guide on how to implement an effective carbide insert regrinding program.

The Case for Regrinding Carbide Inserts

Carbide inserts, essential in many machining operations, are often discarded after their cutting edges become dull. Regrinding these inserts can lead to substantial cost savings by reducing the need for new material. While the grinding and coating processes incur costs, the overall savings, especially for larger inserts, can be significant.

Regrinding also supports sustainability by minimizing waste and reducing the consumption of raw materials. This not only lowers operational costs but also aligns with environmental goals, making it a win-win situation for many companies.

Selecting Regrindable Inserts

Not all carbide inserts are suitable for regrinding. The selection process should consider two main geometry features: the cutting edge and the locating surfaces. Typically, the top surface and primary clearance angle are reground. Inserts with pressed chip breakers on the top surface are not suitable for regrinding, as they cannot be restored to their original geometry. Flat tops or ground top rakes, on the other hand, are compatible with regrinding.

For inserts with side clearance, such as grooving inserts, the width will decrease after regrinding. The change in the cutting edge’s location affects both the centerline and the tool’s length, which determines how many times an insert can be reground. Tools where the cutting edge serves as a locating surface, like many milling inserts, experience doubled changes, making careful planning essential.

Implementing an Effective Tool Management Program

To ensure a successful regrinding program, a robust tool management system is crucial. Inserts must be pulled from service before catastrophic failure occurs, as regrinding can only resharpen intact edges, not repair broken corners. Proper handling and storage are vital; used inserts should be placed in original or suitable containers to prevent further damage. Inserts tossed into bins can suffer from chipping and must be scrapped, negating the benefits of regrinding.

A detailed regrind plan or blueprint should be developed, outlining size changes and regrinding criteria. This plan should specify the minimum usable size after multiple regrinds and conditions for scrapping unfit parts. Responsibilities for sorting and assessing candidates for regrind must be clearly assigned.

Maintaining Quality and Efficiency

Reground inserts need proper labeling and laser marking with regrind information. Tool crib personnel must distinguish between new tools and different levels of reground inserts to avoid production issues. Operators should be informed of the necessary offsets to maintain quality and efficiency.

Get the Most Out of Your Carbide Cutting Tools

Regrinding carbide inserts offers a significant opportunity to reduce tooling costs and promote sustainability in machining operations. With careful planning, proper tool management, and adherence to best practices, companies can successfully implement a regrinding program. This approach not only extends the life of carbide inserts but also contributes to a more sustainable and cost-effective production process by decreasing consumption of the raw carbide and other metals used to produce these tools. 

Call on Knight Carbide for Your Regrinding Needs

At Knight, we have the capacity to regrind carbide inserts and extend their service lives. Every added run beyond their expected capacity puts a little more green in your pocket, and a little less heft to your carbon footprint. Let us show you how it’s done. Call us today at 586-598-4888, or visit us at www.knightcarbide.com today.