A new generation of PVD coatings - mitsubishicarbide.com · A new generation of PVD coatings. 1 PVD...
Transcript of A new generation of PVD coatings - mitsubishicarbide.com · A new generation of PVD coatings. 1 PVD...
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A new generation of PVD coatings
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PVD coatings (Physical Vapour Deposition)PVD is applied to many tools, including drills, end mills, rotating tool inserts, and inserts for diffi cult-to-cut materials.As the coating temperature of PVD is lower (around 700°) than that of other coatings applied to the cutting tools, damage to a substrate during coating is reduced. This maintains the toughness of even sharp edges and a coated layer with superior wear resistance and heat resistance is formed using the latest coating technologies. PVD is applied to tools that require sharp cutting edges and shape maintainability.
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Next-generation PVD
In the past, almost all coating materials have been either TiN or TiCN for improved wear resistance. However, with the rapid development of PVD coating technology, (Al, Ti) N coating with thermal stability has become the most popular coating material in recent years and achieves high quality and performance for the machining of hardened steel and stainless steel, which have been diffi cult-to-cut materials.Through the use of Al-Cr-Ti based components and optimized layer coatings, Mitsubishi Materials continues to take a fresh approach to enable a wide range of different machining applications.
It has already been 30 years since the PVD coating was developed. To satisfy our customers demand for achieving highly efficient machining, Mitsubishi Materials has developed “MIRACLE SIGMA,” which can be used together with products utilizing Mitsubishi’s new PVD coating technology by combining our latest coating technologies with our geometry designing technologies.
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PVD
P P10
P20
P30
P40
PVD
S S10
S20
S30
S40
PVD
M M10
M20
M30
M40
P M S
MP6120/MP6130 MP7130/MP7140 MP9120/MP9130
MP6120
MP9120
MP9130
MP7130
MP6130
MP7140
New PVD Coated GradesMP6100/MP7100/MP9100
ISOCoated Carbide
Ste
el
ISOCoated Carbide
Heat
Res
istan
t Allo
y • T
i Allo
y
ISOCoated Carbide
Sta
inle
ss S
teel
PVD accumulated coating(Each damage measures)
Excellent welding resistance due to low coefficient of friction
Special cemented carbide substrate
Wide range of grades for specifi c materialsMIRACLE SIGMA accumulated Al-Ti-Cr-N based PVD coating
Tool wear
and Damage
Steel Stainless Steel Heat Resistant Alloy • Ti Alloy
Thermal Cracks Notching Welding by Chipping
FeaturesImproved thermal conductivity Improved layer toughness Low affi nty at high temperature
Shape
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S55C SUS304 Ti-6Al-4V
P 0.4M 0.5S 0.3
0.7 0.7 0.7
TOUGH-Σ Technology
P
M
S
2700
1200
1100
1000
900
800
7002800 2900 3000 3100
Hardness (Hv)
Conventional
Oxi
datio
n te
mpe
ratu
re (C
º)
Wear resistance
Hea
t res
ista
nce
A fusion of the separate coating technologies; PVD and multi-layering realises extra toughness.
Multi-layering of the coating prevents any cracks penetrating through to the substrate.
*Graphical representation.
*Graphical representation.
Work Material Grade
Coeffi cient of friction
Measured at 600 degress
Carbon Steel, Alloy Steel MP6100Stainless Steel MP7100
Titanium Alloy, Heat Resistant Alloy MP9100Conventional
MP6100MP7100MP9100
The new technology Al-(Al, Ti)N coating provides stabilisation of the high hardness phase and succeeds in dramatically improving wear, crater and welding resistance.
Best layer of each workpiece
(Al,Cr)N
Tough! Thermal Cracks
TiN
Tough! Notching
CrN
Tough! Resistant Chipping
Base layer High Al-(Al, Ti)N
Dramatically improving the heat and wear resistance!
Excellent welding resistance due to low coeffi cient friction!
PVD accumulated coating
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WSX445
WSX445
Anti Fly Insert mechanism (AFI)
New face milling cutter with innovative double sided insert.Perfect balance between high effi ciency and ease of use.
Designed to control abnormal insert breakage and body damageThe unique conical insert seat and Anti Fly mechanism (AFI) hold the insert securely. The outer edge of the insert is not in contact with the body, thereby preventing damage if sudden fracturing occurs.The thick insert negates the need for a shim.
Through Coolant HolesThrough coolant holes are standard for cutters under 160mm diameter.Improves chip discharge and prevents chip welding.
Single sided insert type
Double sided insert type
Cos
t Per
form
ance
Low resistance
Low cutting resistance, double sided insert face mill for general machining
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WSX445
26°*
31°* 5°─ -5°*
Double sided Z Geometry
Axial centre line
Cutting edge
Unique insert minimizes chatter and vibrationZ Insert Geometry provides low cutting resistanceMitsubishi Materials’ proprietary “Double sided, Z Geometry” insert features a sharp cutting edge with low cutting resistance by utilizing features of both conventional positive and negative rake inserts.
For a sharper cutting edge
For a sharper cutting edge
For higher edge strength
Double sided insert
Single sided insert
Double sided insert
Axial centre line Axial centre lineConventional positive insert Conventional negative insert
*Rake angle mounted an insert.
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Point
Exchangeable Head End Mills
iMX End Mill Series
The iMX series is a revolutionary end mill system that enables effi ciency, high accuracy and rigidity by combining the advantages of both solid carbide and indexable end mills.Security and rigidity close to that of a solid type end mill because the clamping faces are all carbide.Excellent for reduced inventory over a variety of applications due to the exchangeable head.
Available with internal coolant
Special steel screw joint
Mono-block carbide holder
PointDouble face contact type
(Taper + End face)
Steel Steel Cemented carbide
Cemented carbide
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0.3
0.25
0.2
0.15
0.1
0.05
0
100
50
0
iMX
0 0.10 0.12 0.14 0.16 0.18 0.20
EP7020
EP6120
0 2 4 6 8 10 12 14
7.5m 12.5m
Tool life comparison when machining fl at surfaces in Inconel 718EP7020 is a new grade that enables extended tool life when machining diffi cult-to-cut materials.
Work materialHolderHeadRevolutionCutting speedFeed rateDepth of cutProtrusion lengthCutting modeMachine
: Inconel718(43HRC): IMX12-U12N041L100C: IMX12B4HV12012: n=1700min-1
: vc=28m/min: vf=350mm/min (fz=0.05mm/tooth) : ap=0.6mm ae=1.2mm: 65mm: Down cut, Wet (Emulsion): Vertical M/C(BT40)
Cutting length (m)
Competitor B Competitor A
iMX
Max
. Flan
k wea
r at D
.O.C
line
(mm
)
Highly versatile grades
Comparison of tool rigidityThe double face contact of the carbide head and carbide holder gives an increase in rigidity of 30%.
competitorSolid End Mill iMX
Rig
idity
(%)
62mm(i3D)
Loadø20
Strength comparison when slot machining titanium alloyThe reliability of the screw fastening is signifi cantly improved when compared to competitors that employ only steel fastenings. It is also able to cope with high cutting loads.
Work materialHolderHeadRevolutionCutting speed
: Ti-6Al-4V(32HRC): IMX20-U20N030L090C: IMX20C4HV200R10021 : n=1100min-1
: vc=69m/min
Feed rateDepth of cutProtrusion lengthCutting modeMachine
: fz=Above (Expansion): ap=10mm, ae=20mm: 72mm: Wet (Emulsion): Vertical M/C(BT50)
Feed per tooth (mm/tooth)
Competitor A
Competitor B
Breakage at the screw joint
Suitable for high feed milling of steel.
Suitable for milling aluminium.ET2020 (Uncoated)
Breakage at the screw joint
ZERO-μSurface
Smoothed surface“ZERO-μ Surface”
Newly developed(Al, Cr)N group coating
Super-fine particle, super-hard base
material
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VQ-MHV
600
0
(N)
SMARTMIRACLE ®Vibration Control End Mills for Machining Diffi cult-to-Cut Materials
SMART MIRACLE® Coating
SMART MIRACLE coating
Conventional coating
Conventional coating
ZERO-μ SurfaceWith the unique ZERO-μ Surface, the cutting edge retains its sharpness. While previous technologies often resulted in diminished sharpness, the ZERO-μ Surface achieves both smoothness and sharpness, as well as longer tool life.
Smart Miracle end mills have been treated with a newly developed (Al, Cr)N group coating which delivers substantially better wear resistance. The surface of the coating has been given a smoothening treatment resulting in better machined surfaces, reduced cutting resistance and improved chip discharge. This is the next generation of coated end mills that delivers long tool life when machining stainless steels and other diffi cult-to-cut materials.
SMART MIRACLE coating
Work materialEnd millSpindle revolutionCutting speedFeed rateDepth of cutProtrusion lengthCutting modeCoolantMachine
: SUS304: VQMHVD0600(ø6): n=2,650min-1
: vc=50m/min: vf=320mm/min(0.03mm/tooth): ap=6mm: 20mm: Down cut: Emulsion: Vertical M/C (BT50)
Conventional
Cuttingresistance
reduced by more than 20%
Comparison of cutting resistance
Smoothed surface“ZERO-μ Surface”
Newly developed(Al, Cr)N group coating
Super-fine particle, super-hard base
material
ZERO-μSurface
ZERO-μSurface
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MSplus
MSplus MSplus
MS plus (AlTi)N (Al,Cr)N
3,200 2,800 3,100
1,100 800 1,100
100 80 80
10
20
30
4050
60708090100110
120130
140
150
160
170
180 0
3.01
03.
005
3.00
02.
995
2.99
0
2.99
02.
995
3.00
03.
005
3.01
0
10
20
30
40
0
2.99
02.
995
3.00
03.
005
3.01
0
Micro-grain cemented carbide substrate
(Al,Ti, Cr) N Multilayer coating
Seamless cutting edge End cutting edge geometry
Higher wear resistance than conventional products
Excellent wear resistance allows a wide range of applications.
Radius tolerance R±0.005mm
Good surface fi nishes possible even when simultaneously cutting with end and side edges; for example on drafts of dies and moulds.
Sharp but strong cutting edge enables good surface fi nishes.
Sharp edges leave a uniform fi nish.
A dull edge leaves an undefi ned fi nish.
Suitable for fi nishing
<Cutting Condition>Work material : SKD61(HRC38 heat treated steel)Machine : Tapping center (BT20)Cutting Fluid : External emulsion
Carbide end mills
The improved end geometry provides increased sharpness and wear resistance when compared to conventional products.
Hardness (HV)
Oxidation Temperature (°C)
Adhesion (N)
Application Examples
Conventional
Conventional
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DP1020
MVE/MVS
1000
800
2750 2800 2900
Hardness (Hv)
Oxi
datio
n te
mpe
ratu
re (C
º)
Drill SeriesWSTAR
With accumulated Al-Ti-Cr-N based PVD coating
New coated grade DP1020The newly developed DP1020 grade offers excellent wear resistance and reduced friction for longer tool life and a versatile range of applications.
Reduced margin wear DP1020 has excellent wear resistance properties and therefore reduces the amount of material that needs to be removed when re-grinding.
Margin wear after 57m machiningCoventional A
Minor Deep wear marks Wide wear marks
Coventional B
<Cutting conditions>Work material : S50CCutting speed : 100m/minFeed : 0.2mm/revW.S.O (External coolant)
New Generation Solid Carbide Drills
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60.000
48.000
36.000
24.000
12.000
0.0000
MVS
MVE
Coolant fl owspeed increase Velocity (m/s)
Conventional
FluteFlute
Cutting edgeCutting edge
Coolant hole
TRI-cooling Technology®
ZERO-μ Surface
New wavy cutting edge
The unique coolant hole geometry (on drills over ø6) increases the rate of coolant fl ow for improved cooling effect and chip removal.
Our unique smooth surface technology reduces cutting resistance and offers excellent chip evacuation.
The unique wavy cutting edge provides excellent sharpness and rigidity and helps to control wear at the periphery.
CoventionalComparison of wear at the cutting edge periphery (After 57m machining)
<Cutting conditions>Work material : S50CCutting speed : 100m/minFeed : 0.2mm/revW.S.O (External coolant)
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BC8110
BC8110
Peeling of the coating is prevented by improving welding resistance.
Improved wear and chipping resistance.
Improved adhesion to the CBN surface provides increased peeling resistance.
Prevention of welding
TiAlSiN Coating
TiAlN Coating
Newly developed special ceramic coating
Coated CBN Grade for High Hardened Steel Turning
Cutting resistanceForces dispersed in a linear direction can cause sudden fracturing.
Forces dispersed radially help to prevent sudden fracturing.
Cutting resistance
Conventional
CBN sintered body“Ultra Micro-particle Binder”
Dispersal of the new Ultra Micro-particle Binder in BC8110 prevents linear crack development that can cause sudden fracturing.
The newly developed “Ultra Micro-particle Binder” prevents sudden fracture
Medium GrainCBN
Binder macroparticles
Micro Grain CBN
Longer tool life with a coated CBN grade when turning hardened steels.
“Ultra Micro-particle Binder”
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MP9005MP9015
MP9005/MP9015
S05 MP9005
S15 MP9015
3000
2000
1000
25 50
PVD coated grade
ISO Turning Inserts for Diffi cult to Cut Materials
The new technology high Al-rich (Al,Ti)N single layer coating provides stabilisation of the high hardness phase and succeeds in dramatically improving wear, crater and welding resistance.
ISO Grade Grade Concept Application
Top-quality grade focusing on wear resistance Heat Resistant AlloyFinish-Medium Cutting
First recommendation for general applications Heat Resistant AlloyMedium-Rough Cutting
Har
dnes
s of
coa
ting
(Hv)
Soft phaseHigh hardness phase
High Al and conventional coating comparison
Al content (at%)
Conventional technology
New technologyHigh Al-rich (Al,Ti)N Conventional
Substrate
Substrate
P M S
P M S S
P M N S P M N S H
SP M K N S H H
Screw-on Insert type Shoulder Milling Cutter
Screw-on Insert type Face Milling Cutter
Multi-functional Indexable Cutter
High Feed Radius Milling Cutter
For Machining of Aluminium and Titanium Alloys
For Titanium Alloy Milling
Carbide End MillsVibration Control End Mills for Machining Diffi cult-to-Cut Materials
Exchangeable Head End Mills
New Generation Solid Carbide Drills
ISO Turning Inserts for Diffi cult to Cut Materials
Only MVE
≤55HRC
ASX445
ASX400
APX3000APX4000
AJX AXD4000VFX
iMX MS plus
SMART MIRACLE®
MVE/MVS MP9005MP9015
MITSUBISHI MATERIALS CORPORATIONOverseas Sales Dept, Asian RegionKFC bldg., 8F, 1-6-1 Yokoami, Sumida-ku, Tokyo 130-0015, JapanTEL +81-3-5819-8771 FAX +81-3-5819-8774Overseas Sales Dept, European & American RegionKFC bldg., 8F, 1-6-1 Yokoami, Sumida-ku, Tokyo 130-0015, JapanTEL +81-3-5819-8772 FAX +81-3-5819-8774
(Tools specifications subject to change without notice.)URL :
For Your SafetyaDon't handle inserts and chips without gloves. aPlease machine within the recommended application range and exchange expired tools with new ones in advance of breakage. aPlease use safety covers and wear safety glasses. aWhen using compounded cutting oils, please take fire precautions. aWhen attaching inserts or spare parts, please use only the correct wrench or driver. aWhen using rotating tools, please make a trial run to check run-out, vibration and abnormal sounds etc.
2014.10.E(5A)EXP-13-E033
Low cutting resistance, double sided insert face mill for general machining
WSX445
Coated CBN Grade for High Hardened Steel Turning
BC8110