Thick coating improves the service life of indexable inserts

Figure 1 The application of a thick PVD coating on indexed inserts is very successful
Figure 2 Like a pearl chain, the figure shows an indexing blade on a coating device
Figure 3: Since the indexable insert has a PVD coating thickness of 6 μm or more, it can greatly improve the processing efficiency. The coating of 8 to 10 μm is considered to be a very thick coating. PVD technology can now be used for coating to achieve smooth surface quality and lower processing temperatures. After nearly a decade, it is now finally possible to try a PVD coating with a thickness of 8 μm for the first time. This technology has been used very successfully on indexable blades, and PVD technology has opened up a vast application space for itself. This thick PVD coating was developed by CemeCon and can be used in customers' unique coating applications. For example, materials coated with Alox SN2 or gold Alox SN2 can be matched to the requirements of various types of inserts or customers. This coating has been successfully used in milling and turning machining for many years. How do you define a thick coating? In fact, this thick coating is only a few thousandths of a millimeter. At present, most of the coatings with a thickness of between 10 and 12 μm are made by CVD process. The composition of the coating is mainly composed of TiN, TiCN and alumina compounds. However, the trend of technological development and demand is to expand the variety and scope of coating materials. Tool manufacturers are willing to make any combination of aluminum, chromium or silicon to improve the properties of the coating material to meet new requirements. In order to complete this work, only PVD coating technology is currently considered. In this regard, the user can obtain a number of benefits, such as obtaining a very smooth surface and a lower process temperature, so that the problem of material embrittlement does not occur. Today, the oxide layer has no limitations for PVD technology. In the future, new coating materials will be able to adapt to the market and open up new horizons with the help of aluminum, chromium, zirconium and other elemental components. This type of coating material can be combined with super-nitride. Whether it is a typical PVD 3 μm or a thickness of 8 to 10 μm or more, it can be manufactured according to the different edge characteristics and application of the blade. In addition, there are a number of new pre-treatment and secondary treatment methods available, combined with the use of the best coating materials, allows customers to produce a lot of unique products. The benefits of using a thicker coating are obvious. On the one hand, objects can be protected from the influence of cutting processes (eg high temperatures); on the other hand, users can achieve almost 100% longer service life when using double-thickness coatings. Whether it is a currently available CemeCon coating material or a newly developed material in the future, it can be used for turning and rough milling of common steel and cast iron parts. CemeCon has its own line of cutting tools, indexed inserts, shank cutters and hobs in the Wuerselen area and has developed its own coating technology solutions. In these production lines, whether it is processing steps, peripheral equipment and technical equipment, or coating materials, etc., are equipped with the specific requirements of the tool. Through a specific combination of processing steps, coating materials and thicknesses, a wide variety of coatings were achieved, providing customers with capital to compete with their peers. Utilizing its own coating technology and making acquisition plans for the future – these two aspects can provide companies with more opportunities for newly developed PVD technology: Separation of oxide coatings, such as chromium or aluminum based . Coatings of non-thermally conductive cutting materials, such as Si3N4 ceramics. Combined with the advantages of PVD, greater coating thickness can be achieved.

In the past, manufacturers of indexed inserts often explored a variety of technologies to achieve consistent requirements. With the new development trend in the field of PVD development, a variety of different requirements can be met with a single technology in the near future. From milling (finishing or roughing), boring and turning to turning, all or more of these machining processes can be realized with one device. In addition, other cutting materials such as ceramics can also be coated.

There is also environmental protection that is also important in industrial production. The PVD process is an environmentally friendly process that does not produce harmful materials.