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die_mold

die_mold

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Published by shabino75
sandvik coromant
sandvik coromant

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Categories:Types, Brochures
Published by: shabino75 on Feb 14, 2011
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01/15/2015

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CVD

PVD

83

Basically, CVD coating is done through
chemical reactions of different gases. In the
case of coating with titanium carbide; hy-
drogen, titanium chloride and methane.
Inserts are heated to about 1000 degrees C.
Like sintering this is a carefully controlled
process where the carbon content, either
free or as h-phase, has to be monitored
through an extra carburization stage, before
coating. Aluminium oxide coating carried
out in a similar way as is titanium nitride
coating using other gases, aluminium-
chloride or nitrogen gas, respectively. The
CVD process is well adapted to apply
multi layered coatings as the process is
relatively easy to regulate as regards to

various gases. Different types of coating
can be performed in the same equipment.
In the table you can see how different
types of coating methods are affecting the
insert positive (+) or negative (-) in terms
of withstanding different types of wear.
Also shown is how the various types of
coating can cope with the wear-mechanisms;
TiAlN (Titian Aluminium Nitride),
TiCN) (Titanium Carbo Nitride), Al2O3
(Aluminium Oxide), TiN (Titanium
Nitride).

PVD

CVD

MT-CVD

TiAlN

TiN

Ti(C,N)

Al

2O

3

-

+

+

-

+

+

+

o

o

+

o

-

+

o

o

+

o

-

+

o

+

+

-

o

+

o

o

o

o

o

++

-

+*

+

-

-

o

o

o

o

o

o

* Polished

1

2

3

4

5

6

1. Abrasion wear
2. Fatique wear (static or dynamic)
3. Adhesion wear

4. Plastic deformation
5. Chipping/fracture
6. Possibility to make a scharp edge

84

Since steel is the most
common material to
be machined within
the die and mould
area, the Coromant
grades optimized for
steel milling will be
explained a little bit
more in detail.

For the milling operation that need a very
strong cutting edge, where toughness
demands are highest, the GC4040 grade
(P30-P50) provides a new combination of
toughness and wear resistance. A product
of modern coating technology, the grade
copes with the most demanding machining
conditions. The objective has been to achi-
eve high edge security primarily at low to
moderate cutting speeds - yet some 25%
higher than its predecessor.

GC4040 is an insert grade that will not need
for operators to stand next to the stop
button or continually stop the cutter
worrying about the cutting edges for chip-
ping tendencies. If applied correctly, it
copes with strength-demanding steel milling,
unstable conditions, vibration tendencies,
varying workpiece materials and when the
insert is subjected to high cutting forces.

The 90 degree entering angle in milling
leaves insert corners very susceptible to
high machining stresses. Not only radial
forces are high, the entry and exit shock-
forces are often severe. To improve the
edge security, ensuring a long predictable
tool-life, GC4040 is ideal. For the CoroMill
290 square shoulder facemill the grade
offers improvement in performance and

reliability. Also for very demanding opera-
tions, such as die and mould making, the
grade means very high edge strength for
round insert cutters, such as CoroMill 200.
GC4040 can be applied to perform sharp
light cuts as well as high feed roughing
operations and is suitable for use with all
three insert geometries L, M and H. With
or without coolant operations (see cutting
fluid in milling page 95). Also suitable for
castings and forgings, the grade offers new
possibilities for small batch production to
be performed in a productive and very
reliable way.

Allround performance

GC 4030 is more of a general purpose grade,
complementary to 4040. In fact, where 4040
optimizes an area characterized by the
highest strength demands, 4030 optimises
milling of harder steels at higher cutting
speeds and when low feed rates are involved.
There is also a large steel milling applica-
tionarea, where toughness to a varying
extent is needed, and where both insert
grades can be selected.

GC4030 is capable of higher cutting speeds,
offering a higher degree of wear resistance
for operations that are not extreme tough-
ness demanding.

This grade is also a product of advanced
coating technology, having a harder insert
substrate than 4040 but a similar aluminium
oxide coating. GC4030 is especially suitable
as a general, basic grade for use with 45
degree entering angle, such as in CoroMill
245, but also for round insert milling
with CoroMill 200. Dry and wet milling
is possible.

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