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Although coating tools produced in Japan entered the international market relatively late, due to continuous investment in advanced technology, it has entered a leading position in the field of coating tools in the world. Japanese tool manufacturers are constantly researching and developing new technologies and investing in the production of coated tools. This article takes the new technology developed and applied in Mitsubishi Materials as an example to introduce the development of coating tool technology.
1 From the perspective of market demand, the technological development prospects of coated cutters From the perspective of improving product accuracy and quality and reducing environmental pollution, the domestic machinery manufacturing industry has launched a vigorous production technology and processing technology innovation at the production site.
However, in the process of technological innovation, some of the properties of the coated tool did not in fact fully meet the requirements of the user. One of them is the phenomenon of chip adhesion that affects tool life. That is to say, although the coated tool has made great progress in the wear resistance and chipping resistance performance, it is not advanced enough in how to overcome the chip adhesion phenomenon to improve the performance. Damage caused by such chip adhesion phenomenon occurs in the processing of hard-to-cut materials represented by stainless steel and ductile iron. Because it is abnormally worn and unpredictable, the tool life changes a lot. Due to such unstable factors, the index of the number of workpieces that can be processed has to be set lower during processing, which, to some extent, affects the reduction of processing costs.
Therefore, by improving the surface smoothness of the cutting edge of the cutting tool and preventing the adhesion between the cutting tool and the material to be cut, it is particularly important to obtain a cutting insert with improved machining performance. Although these surface-smoothing technologies are aimed at maximizing the abrasion resistance of the coating material itself and thus improving the processing stability, the strategies and methods used by various companies are different, some using mechanical methods and others. It is through the improvement of the coated structure to obtain a smooth-surfaced cutting edge.
2 For products with smooth surface technology, A12O3 films with excellent thermal stability are coated on most substrate materials because the cutting edge is subjected to high temperatures above 500°C within the common processing speed range of CVD coated inserts. The A12O3 coating is a crystalline ceramic. If the coating is too thick to improve the abrasion resistance, the unevenness of the coated surface will increase and the surface roughness will increase. In the cutting process, the material to be cut is easily adhered to the tool surface, and it is difficult to disperse the impact force effectively during intermittent cutting, and it is easy to cause abnormal damage such as built-up edge and chipping.
Mitsubishi Materials Co., Ltd. began its R&D work on the use of coated tool surface smoothing technology to improve the cutting performance of tools and implemented a number of research and development achievements. As the first surface smoothing technology applied to the product, a mechanically smooth surface was applied after CVD coating on a blade grade US7020 for high-speed turning stainless steel. The coated cutter has excellent cutting performance in the machining of stainless steel after coating a multilayered hard film mainly composed of a columnar TiCN film and a fine-grained A12O3 film on a tough cemented carbide substrate. In addition, the use of the surface smoothing technique as described above effectively suppresses the adhesion of the cutting material to the cutting edge. For stainless steel machining, stable tool life is guaranteed even under high-speed cutting conditions of V=200m/min.
In addition, surface smoothing techniques may also be used on representative blade numbers UE6010 and UE6020 for turning steel. The surface smoothing technique applied to the above materials is called “smooth coating technology†and special CVD technology is used to obtain a smooth coating surface by controlling the growth of the coating. It is a non-mechanical treatment that achieves smoothness of the coating surface without damaging the coating.
3 The best “All Black Super Smooth Coating†technology uses the unique combination of chemical surface smoothing technology and mechanical smoothing technology on the latest insert grades UC5105 and UC5115 for turning cast iron. All black super smooth coating." The application of this technology allows the smoothness of the coating surface to be maximized.
In addition to the smooth surface technology, another brand new coating material with high wear resistance also applies to the above grades. For cutting tools, ductile iron is one of the most difficult materials to cut. However, due to the use of UC5105 and UC5115 grades, the abnormal damage of the cutters has been greatly reduced, which solved the problem of ductile iron processing. In addition, the application of UC5105 grade with high hardness cemented carbide as the base material makes it difficult to complete the traditional coating tools, and high-speed machining of cast iron that belongs to the field of ceramic cutting tools has become possible.
This article uses Mitsubishi Materials products as an example to introduce the application of surface smoothing technology in coating technology development. In the future, it will continue to conduct in-depth investigation of market demand and timely develop coating technologies that meet market demands to meet the market demand for coated tool products.
Tool coating surface smoothing technology
At present, in the global machining industry, Japanese machine tools and cutting tools have been highly evaluated for their excellent performance and quality, and are widely used. For indexable inserts, more than half of the coated grades are used to ensure a balance between wear resistance and toughness of the cutting edge.