Precision machining of pure tungsten is challenging due to its unique physical properties. Tungsten has a very high melting point (around 3,422°C or 6,192°F), excellent hardness, and brittleness at room temperature, which make it difficult to machine using conventional methods. Produced via the powder metallurgy process, pure tungsten metal exhibits stratified layers and grain directions further complicating conventional machining.

Here are some of the key difficulties encountered:

1. Hardness and Brittleness

High Hardness: Tungsten’s high hardness makes it resistant to cutting, leading to increased tool wear and the need for specialized, hard cutting tools, typically made of carbide or diamond.

Brittleness: Pure tungsten is quite brittle at room temperature, meaning it can crack or fracture easily during machining. This brittleness necessitates careful control of machining parameters, such as cutting speed, feed rate, and depth of cut, to avoid damaging the material.

2. Thermal Conductivity

Heat Generation: Tungsten’s excellent thermal conductivity causes heat to dissipate rapidly, but the heat generated during machining can still cause thermal damage to cutting tools. This requires the use of appropriate cooling and lubrication techniques to manage heat.

3. Machining Techniques

Preferred Methods: Given its hardness and brittleness, tungsten is often machined using methods like grinding, Electrical Discharge Machining (EDM), or laser cutting, rather than traditional cutting or milling.

Surface Finish: Achieving a high-quality surface finish on tungsten is challenging and may require multiple machining passes with fine adjustments.

4. Tool Wear

Tool Durability: The hardness of tungsten results in significant wear on cutting tools, especially when using traditional machining techniques. Tools need to be frequently replaced or maintained to ensure precision and accuracy.

5. Material Removal Rate

Slow Process: The combination of tungsten’s properties often results in a slow material removal rate, which can increase production time and costs.

Conclusion

Machining pure tungsten requires specialized knowledge, tools, and equipment, and often involves non-conventional methods to overcome the difficulties posed by its physical properties. The challenges of machining tungsten make it essential to carefully plan and control the process to achieve the desired precision and finish​.

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