Application of tools in heat-strength alloys (2)
As a result of these conditions, the C-2, which has been able to process many titanium alloys and nickel-based alloys satisfactorily, suffers from crushing of the cutting edge and severe grooves at the depth of cut when applied to today's alloys. abrasion. However, with the latest fine-grained carbides, high-temperature alloys can be processed efficiently, tool life is improved, and more importantly, reliability is improved in high-temperature alloy applications. Fine-grained cemented carbides have higher compressive strength and hardness than conventional carbides, but add a small amount of cost in terms of toughness. The result is more effective in processing superalloys than conventional hard alloys against common failure modes.
PVD (physical vapor deposition) coatings have also proven effective in processing superalloys. TiN (titanium nitride) PVD coatings were first used and still the most popular. Recently, TiAlN (titanium azide) and TiCN (titanium carbonitride) coatings have also been well used. In the past, the application range of TiAlN coating was more limited than that of TiN. But they are a good choice when cutting speed is increased, increasing productivity by up to 40% in those applications. On the other hand, at lower cutting speeds depending on the surface condition of the coating TiAlN can cause built-up edge, subsequent micro-cracking and groove wear.
Recently, materials for superalloy applications have been developed, and these coatings are composed of several layers. Extensive laboratory and field testing has demonstrated that this combination is effective over a wide range of applications compared to any other single coating. Therefore, PVD composite coatings for superalloy applications may become the focus of research and development of new cemented carbide materials. Together with MTCVD coatings and coated ceramics, they are expected to be the main impact force for more efficient processing of new, more difficult to machine workpiece materials being developed.
Dry cutting
The problem, including coolant, is another area in which the technology and commercialization of tool manufacturing expands the trend of industrialization. Strict coolant management requirements in North America and Europe and the three largest automakers force their core suppliers to obtain ISO14000 certification (ISO9000 environmental management version), which increases coolant handling costs. One of the most popular reactions to automotive companies and their core suppliers is the complete elimination of coolant usage in specific processing applications. This new world of dry machining presents a number of challenges for tool suppliers.
Recently, there have been some very useful and comprehensive technical articles on this topic that reveal speed, feed, coating chemistry and other parameters. Here I would like to focus on the new “dry processing perspective†of automakers in terms of operational and commercial meaning.
Metalworking practitioners have a good understanding of the use of coolants, but most do not understand dry machining issues other than technical challenges between tool-to-workpiece contact surfaces (eg chip removal). It is generally observed that the effluent coolant disperses the chips, but high-speed coolants with pressures in excess of 3,000 psi can also help with chip breaking, especially soft and continuous swarf that can cause trouble on the tool-workpiece interface.
The result of parts using dry cutting processes is that the machine is hotter than wet parts. Do you allow them to cool naturally in the open before measuring? If the newly machined hot parts are often placed in the tote, raise the ambient temperature, is the part sufficiently cooled and just enough to allow for accuracy detection? There are also dozens of parts around the disposal that add extra burden to the operator.
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