Composite Tool Coatings by NanoMech, Inc. All rights reserved.

Transcription

1 Composite Tool Coatings

2 TuffTek Composite Tool Coatings Using technology developed in the field of nano-materials, TuffTek was originally designed as an alternative for PCBN for machining steels above Rc 45 in hardness. TuffTek has been shown to excel in finishing and semi-finishing hard turning applications at a fraction of the cost of brazed or solid PCBN.

3 Introduction to TuffTek is a major breakthrough in insert coatings o Combining the extreme hardness of cubic boron nitride Second Hardest Man-made Material o With the industry-recognized standard titanium nitride (gold) coating o To create a holy grail of coated inserts This new generation Hybrid coating is manufactured in two steps o o Electrostatic spray coating (ESC) for the deposition of cbn coating preform (porous) Chemical vapor infiltration (CVI) of ceramic binder (eg., titanium nitride (TiN), titanium carbon nitride (TiCN), etc) at around 1000 o C for binding cbn particles.

4 Numerous Advantages Over Conventional Coatings and PCBN Increased tool life and potential productivity in turning operations over competitive coatings Excellent surface finish Cost advantages over PCBN in hard turning Cost effectiveness advantages over PVD TiAlN May be used either wet or dry Economical way to increase part quality and production profits Allows the use of chip breaker insert geometries rather than the flat top rake required by PCBN Allows the usage of inserts with cbn coating and sharp edge (No T-land or K-land), reducing the tool pressure on workpieces and improving surface integrity.

5 Exactly What is cbn-tin Composite Coating? Strong and Tough! TuffTek is a high performance 3-D coating unlike anything on the cutting tool market today Unlike other multi-layer tool coatings which stack layer upon layer, TuffTek uses a patented process to deposit a layer of super hard cbn particles on carbide inserts Then the cbn particles are infiltrated with TiN or other coatings to act as a binder. The resulting true composite coating is extremely hard (cbn) and wear resistant (TiN). TiN WC-Co cbn-tin 1000 Actual Photomicrographs of TuffTek cbn-tin Composite Coatings on a CNMG-432 Turning Insert

6 TuffTek cbn-tin Coating Steps Carbide Substrate (insert without coating) Carbide Substrate With Cubic Boron Nitride Nanoparticles Applied to Surface 100 Carbide Substrate With cbn Nanoparticles Infiltrated with Titanium Nitride

7 Sample Applications Threaded shaft Brake Drum Connecting Rod Stub Axle Flywheel Finishing

8 Is Suitable for Machining Wet or Dry

9 Material Coating Options are Numerous Using our state-of-the-art technology, virtually any insert style can be coated with TuffTek

10 Example Test Comparatives

11 Comparison of PVD TiAIN vs TuffTek Flank wear,mm Competitor Initial wear progression Plateau zone TuffTek PVD TiAlN Accumulated machining time, min Expedited wear zone ISO 3685 Standard for single-point cutting for semi-finish and finishing turning Cutting insert: cbn-tin coated CNMG 432A-4U; Material: AISI 4340 hardened steel (50~53 HRC); cutting speed: 150 m/min, feed rate: 0.15 mm/rev, depth of cut: 0.25mm. Wear criterion is selected as 0.2 mm (ISO 3685). PVD TiAlN coated CNMA 432 inserts showed a life of 4 mins at V=125m/min, f=0.15mm/rev, DoC=0.25mm

12 20X Runtime Advantage for TuffTek over PVD TiAIN! Minutes to Failure TuffTek Minutes to Failure PVD TiAIN Surface speed: 150 m/rev, F=0.15 mm/rev, DoC=0.25mm. AISI 4340 with hardness of 50~52 HRC. Insert style: CNMA432 with no edge prep; ISO 3685 for tool failure criteria.

13 2-8x More Durable Than Leading Alternatives

14 More Examples Tool Failure Analysis o o o Same style and grade of substrate; different coating Longitudinal & Continuous With Cutting Fluid

15 And without Cutting Fluids

16 And Those Results Wear Progression o Longitudinal & Continuous o Without Cutting Fluid

17 Summary of Advantages Increased tool life Better annual cost-of-ownership Potential to increase productivity for turning operations Excellent surface finish Chip control Good dimensional control May be used either wet or dry

18 What the Press Are Saying

19 Thank You! Let NanoMech s dedicated team of scientists, engineers, technicians, and management professionals develop a coating solution for your difficult turning applications. Composite Tool Coatings