Leading technical analysis of Japanese machine tools and coated tools
Although the coated tools produced in Japan entered the international market late, due to continuous investment in advanced technology, it has entered the leading position in the world of coated tools. Japanese tool manufacturers are working day and night to develop new technologies and invest in the production of coated tools. This article introduces the development of coated tool technology by taking the new technology developed and applied by Mitsubishi Materials as an example.
1. Prospect of technical development of coated tools from market demand
From the perspective of improving product accuracy and quality and reducing environmental pollution, Japan's domestic machinery manufacturing industry has launched a vigorous production technology and processing technology innovation at the production site.
However, in the process of innovation in processing technology, some properties of coated tools have not fully met the requirements of users, and chip bonding, which affects tool life, is one of them. That is to say, although the coated tool has made great strides in wear resistance and chipping resistance, it is not advanced enough to overcome the chip sticking phenomenon to improve performance. This damage caused by the chip bonding phenomenon occurs in the processing of difficult-to-cut materials typified by stainless steel and ductile iron. Because it is abnormally worn and unpredictable, the tool life changes a lot. Due to such unstable factors, it is usually necessary to set the number of machinable workpieces to be low during processing, which affects the reduction of processing cost to some extent.
Therefore, it is particularly important to improve the surface smoothness of the cutting edge of the tool to prevent the tool from sticking to the material to be cut, thereby obtaining a cutting insert with improved machining performance. Although these surface smoothing techniques are aimed at maximizing the wear resistance of the coating material itself and improving the processing stability, the strategies and methods adopted by each company are different, some are mechanical methods, and some are mechanical. This is achieved by improving the coating structure to obtain a smooth cutting edge.
2. Products for smooth surface technology
In the range of processing speeds commonly used for CVD coated inserts, most of the base material is coated with an A12O3 film with excellent thermal stability because the cutting edge is subjected to a high temperature of 500 ° C or higher. The A12O3 coating is a crystalline ceramic. If it is applied too thick to improve the wear resistance, the unevenness of the surface of the coating will increase and the surface roughness will increase. During the cutting process, the material to be cut is easy to adhere to the surface of the tool, and it is difficult to effectively disperse the processing impact force during intermittent cutting, which may easily lead to abnormal damage such as built-up edge and chipping.
Mitsubishi Materials has long been conducting research and development work to improve tool cutting performance by using coated tool surface smoothing technology, and has implemented a number of research and development results. As the first surface smoothing technology applied to the product, the surface smoothing technique of mechanical treatment was carried out after CVD coating on the blade grade US7020 for high-speed turning stainless steel. After coating a tough hard alloy substrate with a multi-layer hard film mainly composed of a columnar crystal TiCN film and a fine particle A12O3 film, the coated tool shows excellent cutting performance in the cutting process of stainless steel. In addition, the surface smoothing technique as described above is used to effectively inhibit the bonding of the material to be cut on the cutting edge. For stainless steel machining, stable tool life is guaranteed even under high-speed cutting conditions of V = 200 m/min.
In addition, surface smoothing techniques can also be employed on representative blade grades UE6010 and UE6020 for turning steel. The surface smoothing technique applied to the above materials is called “smooth coating technology†and uses a special CVD technique to obtain a smooth coating surface by controlling the growth of the coating. It is a non-mechanical treatment that achieves smooth surface finish without damaging the coating.
3. The best "all black super smooth coating" technology
On the latest insert grades UC5105 and UC5115 for turning cast iron, the unique chemical treatment of surface smoothing technology and mechanical smoothing technology combined with a comprehensive surface treatment technology - "all black super smooth coating". The use of this technology maximizes the smoothness of the surface of the coating.
In addition to the smooth surface technology, another new coating material with high wear resistance technology is also suitable for the above grades. Ductile iron is one of the most difficult materials to cut for cutting tools. However, due to the application of the UC5105 and UC5115 grades, the abnormal damage of the tool is greatly reduced, and the problem of processing the ductile iron is solved. In addition, the application of the UC5105 grade with high-hardness cemented carbide as the base material makes it difficult to complete the high-speed machining of cast iron in the field of ceramic tool cutting.
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