1 Progress in tool materials In today's fast-growing manufacturing industry, cutting operations play an important role. Manufacturing economics believes that by increasing the efficiency of cutting and reducing the proportion of fixed costs in manufacturing costs, the total cost of parts manufacturing is greatly reduced, which is an effective way to improve the competitiveness of the enterprise market.
The performance of tool materials is the basis and key technology to improve tool cutting efficiency. The progress of the tool materials presented in this exhibition is characterized by the development of new grades of tool materials to make them more adaptable to the materials being processed and the cutting conditions, thus achieving the goal of improving cutting efficiency.
First of all, the development of new grades is highly targeted. Faced with complex and diversified applications and processing conditions, tool manufacturers have adopted the “precautionary medicine†approach and achieved remarkable results. For example, Kennametal has only introduced new grades for machining different materials: KC9110 for processing steel, KC9225 for processing stainless steel, KY1310 for processing cast iron, KC5410 for processing heat-resistant alloy, KC5510 for processing hardened materials, and processing non-processing. KY1615 iron material. The new grade can increase the cutting efficiency by 15%~20% on average. The new grades of TK1000 and TK2000 for processing cast iron introduced by Seco are 20%~30% higher than the TX100 and TX150 which were introduced two years ago. The TP3000 developed by the company for heavy-duty cutting, interrupted cutting and large There is good reliability in the application of the feed.
Cast iron and stainless steel are two kinds of materials currently used in many applications. It is common to improve the processing efficiency of these two materials. However, the processability of the two materials is very different. Many companies have exhibited the processing of these two materials. Special grade. For example, Zhuzhou Diamond Cutting Tool Co., Ltd. exhibited the black diamond blade series (Fig. 1), which is a carbide insert specializing in machining cast iron, covering various applications, including YBD052, which can dry high-speed machining of gray cast iron. YBD102 for spheroidal graphite cast iron, YBD152 for medium and high speed or milling, and YBD252 for medium and low speed wet milling or intermittent machining. The test data shows that these new grades can increase the cutting speed by 30%~40% and the service life can be increased by nearly 40%~50%. The company's YC30T and YC40T are specially processed stainless steel grades. The former can be used 250m/ Min's high-speed machining of 1Cr18Ni9Ti, while the latter can feed large-depth deep-cut stainless steel, improve processing efficiency and reduce processing costs by 30%.
Secondly, in the development of new grades, the optimized combination of matrix and coating is emphasized, and only in this way can the purpose of adaptive development be better achieved. For high-speed machining grades, the base should have a high resistance to plastic deformation and a cobalt-rich surface and a coating resistant to crescents; for intermittent cutting grades with impact, the substrate and coating should be better Resilience. Sandvik's special grades for turning cast iron, GC3205, GC3210, and GC3215, are CVD coated cemented carbides, which are used for high-speed machining of gray cast iron, high-speed machining of ductile iron, and medium- and low-speed intermittent cutting of various cast irons. The three grades are made of different cemented carbide substrates and different thicknesses of Al2O3 and MT-TiCN coatings (Fig. 2). Japan's Mitsubishi Materials Corporation UC5105, UC5115 hard alloy CVD coating grade for cast iron, the former for high-speed continuous cutting of gray cast iron or ductile iron, using a high hardness matrix, the latter for the unstable processing of ductile iron A tough matrix is ​​used; both are coated with particulate Al2O3 and particulate and fibrous TiCN thick films. BOEHLERIT's cast iron grade Casttec LC620H uses a tough matrix for interrupted cutting, while Al2O3's surface coating reduces crater wear and has an interlocking intermediate layer to increase bond strength. 400m/min high speed machining of gray cast iron.
In processing stainless steel, Sandvik's GC2015 for turning austenitic stainless steel is a matrix with gradient zone resistance to plastic deformation and improved thermosetting, plus TiN-TiN/Al2O3 (multilayer) designed for this grade - TiCN coating and smoothing the surface of the coating improves the resistance to abrasive wear, flaking and chipping resistance. KORLOY's PC9530 is a graded stainless steel grade with an ultra-fine particle substrate and PDV coating.
The role of coatings in the development of new grades is also reflected in the development of new grades for ceramics, cermets and PCBN. These materials improve the toughness by properly sacrificing the hardness of the matrix and then applying an abrasion resistant coating to provide wear resistance. Obtaining a comprehensive performance of toughness and wear resistance, becoming a new grade, expanding the application field, such as the PVD TiAlN coated grade of TaeguTec's PV3010 cermet substrate. Another example is Kenner's KY315 PVD TiN/TiCN/TiN coated cermet insert, which expands the processing range, long tool life and good surface quality.
Third, the development of new grades usually includes the corresponding improvement of the groove shape and geometric parameters to better adapt to the characteristics of the material to be processed and the requirements of different processes for chip breaking, and to reduce the cutting force and reduce vibration. Make cutting more brisk and efficient. Figure 3 shows the four trough shapes corresponding to the four UE series carbide inserts developed by Mitsubishi Materials Corporation for processing steel. According to CemeCon, the company cooperated with the Swiss company Fraise to develop the corresponding coating according to the material, geometry and application of the Fraise milling cutter to ensure the best combination of the three and achieved good results.
The strong momentum of the development of the new grades displayed at the exhibition shows the obvious advantages of large tool manufacturers with material and coating development capabilities in the development of new products. They use the comprehensive strength in the development of tool materials and coatings. Continuous research and development of new manufacturing process technology, improvement of existing grades, improvement of cutting processing efficiency, leading the advancement of cutting technology, and also in a favorable position in the market competition. The facts show that in today's cemented carbide as the main tool material, and the overall progress of various tool materials, tool materials and coatings are the core technology of a tool enterprise. It is difficult for a tool company that does not have this core technology to be strong. Be big. Some big companies can last for a long time, and South Korea's TaeguTec, KORLOY, and DINE can rise rapidly and they have a close relationship with this core technology.
A similar situation has occurred in the field of high-speed steel tools. The high-speed steel milling cutters of DORMER exhibiting a new generation of powder metallurgy cobalt high speed steel (HSCO-XP) developed in cooperation with high-speed steel manufacturers. Compared with the powder metallurgy high-speed steel produced by the general method, this high-speed steel removes more than 90% of the impurities during the smelting process (Fig. 4), and the strength is increased by 20%, thereby significantly reducing the chipping of the tool and improving the tool. Reliability and reduced downtime. The company also collaborated with institutions of higher learning to develop a Super R coating for milling. It is a composite coating with a TiN layer on top and a multi-layer coating on it. It has good physical and mechanical properties (hardness 2800~3000Hv). The bonding strength is 50~70N, the oxidation resistance temperature is 450~500°C, and the friction coefficient is 0.3~0.4).
2 Diversification and serialization of tool coatings In the development of modern cutting technology, the contribution of coating technology and its role in improving cutting efficiency are becoming more and more prominent, and are highly concerned by tool manufacturers and tool users. expand. According to Kennametal experts, the company's proportion of coated tools is 85%. At this exhibition, you can see the progress made by the professional coating company for the development of new PVD coating technology and equipment, as well as the tool manufacturers' application of coating technology to develop new coating grades. Achievements. In the interview, CemeCon experts introduced the company's CC800/9 coating equipment (Figure 5) with good flexibility, from coating simple TiN to Supernitride series coatings and oxide coatings, up to 30 High-performance coating, users can control the composition of different components, different tissues and structures by controlling the gas, pressure, workpiece table rotation speed, bias voltage, magnetic field and other parameters according to the specific coating performance required. Floor. The company provides open software and trains users on self-development work. This is also a common feature of other coating company equipment exhibiting.
The performance of tool materials is the basis and key technology to improve tool cutting efficiency. The progress of the tool materials presented in this exhibition is characterized by the development of new grades of tool materials to make them more adaptable to the materials being processed and the cutting conditions, thus achieving the goal of improving cutting efficiency.
First of all, the development of new grades is highly targeted. Faced with complex and diversified applications and processing conditions, tool manufacturers have adopted the “precautionary medicine†approach and achieved remarkable results. For example, Kennametal has only introduced new grades for machining different materials: KC9110 for processing steel, KC9225 for processing stainless steel, KY1310 for processing cast iron, KC5410 for processing heat-resistant alloy, KC5510 for processing hardened materials, and processing non-processing. KY1615 iron material. The new grade can increase the cutting efficiency by 15%~20% on average. The new grades of TK1000 and TK2000 for processing cast iron introduced by Seco are 20%~30% higher than the TX100 and TX150 which were introduced two years ago. The TP3000 developed by the company for heavy-duty cutting, interrupted cutting and large There is good reliability in the application of the feed.
Cast iron and stainless steel are two kinds of materials currently used in many applications. It is common to improve the processing efficiency of these two materials. However, the processability of the two materials is very different. Many companies have exhibited the processing of these two materials. Special grade. For example, Zhuzhou Diamond Cutting Tool Co., Ltd. exhibited the black diamond blade series (Fig. 1), which is a carbide insert specializing in machining cast iron, covering various applications, including YBD052, which can dry high-speed machining of gray cast iron. YBD102 for spheroidal graphite cast iron, YBD152 for medium and high speed or milling, and YBD252 for medium and low speed wet milling or intermittent machining. The test data shows that these new grades can increase the cutting speed by 30%~40% and the service life can be increased by nearly 40%~50%. The company's YC30T and YC40T are specially processed stainless steel grades. The former can be used 250m/ Min's high-speed machining of 1Cr18Ni9Ti, while the latter can feed large-depth deep-cut stainless steel, improve processing efficiency and reduce processing costs by 30%.
Secondly, in the development of new grades, the optimized combination of matrix and coating is emphasized, and only in this way can the purpose of adaptive development be better achieved. For high-speed machining grades, the base should have a high resistance to plastic deformation and a cobalt-rich surface and a coating resistant to crescents; for intermittent cutting grades with impact, the substrate and coating should be better Resilience. Sandvik's special grades for turning cast iron, GC3205, GC3210, and GC3215, are CVD coated cemented carbides, which are used for high-speed machining of gray cast iron, high-speed machining of ductile iron, and medium- and low-speed intermittent cutting of various cast irons. The three grades are made of different cemented carbide substrates and different thicknesses of Al2O3 and MT-TiCN coatings (Fig. 2). Japan's Mitsubishi Materials Corporation UC5105, UC5115 hard alloy CVD coating grade for cast iron, the former for high-speed continuous cutting of gray cast iron or ductile iron, using a high hardness matrix, the latter for the unstable processing of ductile iron A tough matrix is ​​used; both are coated with particulate Al2O3 and particulate and fibrous TiCN thick films. BOEHLERIT's cast iron grade Casttec LC620H uses a tough matrix for interrupted cutting, while Al2O3's surface coating reduces crater wear and has an interlocking intermediate layer to increase bond strength. 400m/min high speed machining of gray cast iron.
In processing stainless steel, Sandvik's GC2015 for turning austenitic stainless steel is a matrix with gradient zone resistance to plastic deformation and improved thermosetting, plus TiN-TiN/Al2O3 (multilayer) designed for this grade - TiCN coating and smoothing the surface of the coating improves the resistance to abrasive wear, flaking and chipping resistance. KORLOY's PC9530 is a graded stainless steel grade with an ultra-fine particle substrate and PDV coating.
The role of coatings in the development of new grades is also reflected in the development of new grades for ceramics, cermets and PCBN. These materials improve the toughness by properly sacrificing the hardness of the matrix and then applying an abrasion resistant coating to provide wear resistance. Obtaining a comprehensive performance of toughness and wear resistance, becoming a new grade, expanding the application field, such as the PVD TiAlN coated grade of TaeguTec's PV3010 cermet substrate. Another example is Kenner's KY315 PVD TiN/TiCN/TiN coated cermet insert, which expands the processing range, long tool life and good surface quality.
Third, the development of new grades usually includes the corresponding improvement of the groove shape and geometric parameters to better adapt to the characteristics of the material to be processed and the requirements of different processes for chip breaking, and to reduce the cutting force and reduce vibration. Make cutting more brisk and efficient. Figure 3 shows the four trough shapes corresponding to the four UE series carbide inserts developed by Mitsubishi Materials Corporation for processing steel. According to CemeCon, the company cooperated with the Swiss company Fraise to develop the corresponding coating according to the material, geometry and application of the Fraise milling cutter to ensure the best combination of the three and achieved good results.
The strong momentum of the development of the new grades displayed at the exhibition shows the obvious advantages of large tool manufacturers with material and coating development capabilities in the development of new products. They use the comprehensive strength in the development of tool materials and coatings. Continuous research and development of new manufacturing process technology, improvement of existing grades, improvement of cutting processing efficiency, leading the advancement of cutting technology, and also in a favorable position in the market competition. The facts show that in today's cemented carbide as the main tool material, and the overall progress of various tool materials, tool materials and coatings are the core technology of a tool enterprise. It is difficult for a tool company that does not have this core technology to be strong. Be big. Some big companies can last for a long time, and South Korea's TaeguTec, KORLOY, and DINE can rise rapidly and they have a close relationship with this core technology.
A similar situation has occurred in the field of high-speed steel tools. The high-speed steel milling cutters of DORMER exhibiting a new generation of powder metallurgy cobalt high speed steel (HSCO-XP) developed in cooperation with high-speed steel manufacturers. Compared with the powder metallurgy high-speed steel produced by the general method, this high-speed steel removes more than 90% of the impurities during the smelting process (Fig. 4), and the strength is increased by 20%, thereby significantly reducing the chipping of the tool and improving the tool. Reliability and reduced downtime. The company also collaborated with institutions of higher learning to develop a Super R coating for milling. It is a composite coating with a TiN layer on top and a multi-layer coating on it. It has good physical and mechanical properties (hardness 2800~3000Hv). The bonding strength is 50~70N, the oxidation resistance temperature is 450~500°C, and the friction coefficient is 0.3~0.4).
2 Diversification and serialization of tool coatings In the development of modern cutting technology, the contribution of coating technology and its role in improving cutting efficiency are becoming more and more prominent, and are highly concerned by tool manufacturers and tool users. expand. According to Kennametal experts, the company's proportion of coated tools is 85%. At this exhibition, you can see the progress made by the professional coating company for the development of new PVD coating technology and equipment, as well as the tool manufacturers' application of coating technology to develop new coating grades. Achievements. In the interview, CemeCon experts introduced the company's CC800/9 coating equipment (Figure 5) with good flexibility, from coating simple TiN to Supernitride series coatings and oxide coatings, up to 30 High-performance coating, users can control the composition of different components, different tissues and structures by controlling the gas, pressure, workpiece table rotation speed, bias voltage, magnetic field and other parameters according to the specific coating performance required. Floor. The company provides open software and trains users on self-development work. This is also a common feature of other coating company equipment exhibiting.
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Maghard Flexible Magnet Co., Ltd. , http://www.dg-magnet.com