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|WD2||Mushroom-shaped carbide socket|
|-12F||12 mm PCD tip diameter, flat geometry|
|HT11||Base body for quick-change toolholder system HT11|
|X²||Generation identification /product characteristic|
|Quantity per toolbox||5 pieces|
|Weight per toolbox||13.0 kg|
|Number of interlayers||0|
PCD milling tools are perfectly suitable for surface course rehabilitations and (micro) fine milling applications due to their tool geometry and materials.
They feature a highly wear-resistant tool tip made of polycrystalline diamond (PCD) with an extremely long service life.
The very slight lengthwise wear ensures optimum evenness over the milled surface and consistently high machine feed.
Depending on their application, PCD milling tools are a useful addition to the existing pick range featuring conventional carbide tips.
1 Highly wear-resistant PCD tip ensures a consistent, even milling pattern is achieved for the tool’s entire service life thanks to the significantly reduced lengthwise wear.
2 High resistance of the tip is ensured by damping the impacts caused by penetration by so called interlayers.
3 Large carbide socket volume ensures greater wear resistance and optimal use of the polycrystalline diamond tip.
4 Solid chip breaking web extends the protection of the carbide socket against washout and thus the service life of the tool considerably.
5 Reliable HT22 interface ensures low-maintenance, dependable use of WIRTGEN PCD milling tools.
PCD AND ITS MANUFACTURING PROCESS
PCD (polycrystalline diamond) is a highly sophisticated, synthetically manufactured, strong mass of carbon and carbide. The PCD tip consists of differing layers: A concentrate of diamond particles in the upper layer, the interlayers and a tungsten carbide substrate. Basically a PCD tip is a crystalline diamond coated carbide tip. Manufacturing facts:
> High-pressure: 55,000 bar–85,000 bar (5.5 GPa–8.5 GPa)
> High-temperature synthesis: 1,400 °C–1,800 °C (2,500 °F–3,300 °F)
> High-pressure high-temperature press to manufacture PCD tips.
IMPROVED PCD TIP DURABILITY
Interlayers are the unique WIRTGEN solution to dampen the impact stresses between the tungsten carbide substrate and the highly wear resistant polycrystalline diamond contact surface. The interlayers subsequently enhance the durability and reliability of the PCD contact surface. This special tip design allows use in a wider range of applications.
PCD PERFORMANCE EVALUATION
Many factors must be taken into account when making a cost /performance analysis of conventional carbide tools compared with PCD milling tools. Besides usage and application cases, purchase costs must also be considered for the two tool types (carbide and PCD) and their variants along with varying associated costs incurred due to the carbide and PCD charge weight. There are enormous variations in potential cost-effectiveness due to these costs and varying service lives alone.
Lower maintenance expenses thanks to an absence of pick replacement or lower costs related to pick wear also bring further advantages in terms of savings per milled tonne or per m³.
WIRTGEN PCD IN COMBINATION WITH MCS / FCS INCREASES FLEXIBILITY
WIRTGEN’s MCS (Multiple Cutter System) and the predecessor version, FCS (Flexible Cutter System), allow milling drums of the same width to be changed quickly and easily, typically within two hours. Thus one machine can be used for a broad range of applications with minimal downtime when exchanging drums. The high level of flexibility ideally compliments the PCD milling tool technology. This means the appropriate more economical pick tipping (carbide or PCD) can be selected for the application concerned and the entire milling drum rapidly replaced with one of the same working width. The cold milling machine is soon ready for use again.
ADVANTAGES OF THE WIRTGEN PCD IN COMBINATION WITH HT22
Time spent on toolholder maintenance and replacement are crucial factors in any application. The HT22 toolholder in combination with PCD milling tools gives advantage over all other available toolholder systems by reducing this maintenance time. The maintenance requirements of the HT22 (e.g. tightening of bolts) is in line with the life time of the PCD tool upper section (carbide PCD combination).
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