Whether it’s tool preparation , the coating stage or the post-treatment of the layer , we don’t leave anything to chance. Each individual process step is designed to provide the best possible tool solution for your machining processes.
Tool preparation
The microgeometry of a machining tool (i.e. the contour of the cutting edge) plays a key role in its performance.
Tools with a positive rake angle and sharp cutting edges have excellent cutting properties, but this also means the cutting edges are less sturdy. A less sturdy cutting edge is very susceptible to parts breaking off , which would result in a poor-quality workpiece surface and in the tool life being reached prematurely .
Defined rounded cutting edges ensure:
- Improved coating adhesion.
- A sturdier cutting edge.
- Much longer tool life and higher tool productivity.
1) Non-rounded cutting edge.
2) Defined rounded cutting edge.
Coating and layer post-treatment
Coatings prevent direct contact between the material being machined and the blade material, which reduces wear caused by adhesion, abrasion, diffusion or oxidation.
One of the best-known coating methods used for machining tools is PVD (Physical Vapour Deposition), which is when a solid metallic material (target) is vaporized in a vacuum .
In many cases the actual coating is formed by the additional use of a reactive gas . The vaporous coating material ultimately condenses on the substrate as a thin layer , creating the tool coating.
A particularly widespread PVD technology used in industrial applications is cathodic arc deposition (or Arc-PVD for short) , which offers a very high deposition rate .
1) Coating on an untreated tool surface.
2) Coating on a pretreated tool surface.
Smoothing
During Arc-PVD, the target material is vaporized at the cathode spot of an electric arc by the high energy density . However, this process forms molten particles (droplets) which are deposited on the substrate and leave behind microscopic imperfections.
We use special post-treatment processes to smooth out these and similar rough areas on the surface, which reduces friction and extends the tool life .
1) Tool surface with droplets.
2) Tool surface without droplets.
Polish grinding
By optimizing the chip spaces for specific materials , we ensure controlled chip evacuation and that the tool does not clog up.
Polished chip spaces have a very smooth surface for optimized chip evacuation when machining non-ferrous metals with a high volume of chips.