Global users of the Gospel: a new generation of cutting tool materials, can increase production efficiency by 300%
The industry's fans are expectants. Walter, headquartered in Tübingen, raised expectations at the Stuttgart International Metalworking Exhibition (AMB 2016) in 2016. The new generation of cutting tool materials Walter 's Tiger • tec Gold Tiger) represents the leap in the industry as a whole, and the first piece of indexable inserts with new coating at the beginning of 2017 was one of the things that was clear: the Tübingen processing and development experts were very real and not exaggerated at all.
Wolfgang Vötsch, Walter Senior Milling Product Manager, stressed: 'We have received countless customer feedback on product innovation.' There are countless users around the world using Tiger • tec Gold. They all recognize new quality and new features.
This is not surprising: customers come from different industries, such as the automotive industry and the energy industry, or mold manufacturing and mechanical engineering. They continuously report Tiger • tec Gold's unprecedented good results. 'According to records, some cases of performance An increase of one hundred percent. Almost all applications, the tool life is 2 to 3 times the traditional tool.
Fundamental innovation
Over the past two decades, the cutting tool materials for the global processing industry are based on titanium carbonitride and alumina, and of course the properties of these coatings have been optimized over the years, but their limitations are becoming more and more obvious. For example, the materials used in high-tech, aerospace and automotive industries are becoming increasingly difficult to cut, and the nature of the coating required is that the conventional coating is almost impossible to meet the requirements.Compared with existing solutions, the required tools require more wear , The efficiency should be higher.
Wolfgang Vötsch said: 'We are looking for fundamental changes over the years, and we are also at the forefront of the development of this field, and we have achieved it.'
Caption: Wolfgang Vötsch, Walter's Senior Milling Product Manager, said: 'We have been seeking fundamental change for years and we are also at the forefront of development in this area.' And he confidently states: 'We've achieved that.'
Walter, based in Tübingen, is using Tiger • tec Gold to build a brand new platform based on TiAlN, developed using a newly developed CVD coating process that is best suited for medium and high speed milling of steel due to the unique properties of this material Pieces and cast iron workpieces.
Tool life extension of about 80%
Prior to the launch, Wal-Mart's R & D staff conducted a wide range of on-site tests on the new Tiger • tec Gold WKP35G material, and as expected, the test results showed that improvements in three areas were particularly pronounced, as confirmed in practice Flank wear resistance is particularly good, the formation of slow hair crack growth resistance to plastic deformation ability, using WKP35G coating tool performance is excellent.
The initial field test results show that the overall life expectancy increased by 80% on average, but today the market has reported an average performance increase of 100% - 200% .WolfgangVötsch said: 'At the highest level, the tool life can be extended by 300%, not just a Some special applications, but using different parts and materials - from structure, alloy and stainless steel to gray cast iron, dense ductile iron.
An application engineer at Walter's customer said: "The new material is much better than the original compact ductile iron." Another engineer was also amazed: 'The wear is too low and you can not see anything.I was initially skeptical about changing blades But in fact they did not change.
Since Tiger • tecGGold went public, the following parts have been treated with the new coating and worked well:
- Engine body made of GG25 (gray cast iron)
- Machine bed made of GG25 (gray cast iron)
- Excavator support plate made of St42 (structural steel)
- Drive shaft made of 35CrMo (alloy steel)
- Glass bottle mold made of GG25 (gray cast iron)
- Connecting rod made of C70 (alloy steel)
- Knuckle made of GG25 (gray cast iron)
The main reason for the significantly improved performance of the new generation of cutting tool materials is their unique coating properties: TiAlN has a high aluminum content of about 85% because of its high hardness, especially because of its compressive residual stress and excellent performance.
The world's unique technology
Walter engineers have developed a completely new manufacturing process that supports a series of depositions of TiAlN, a combination of ULP-CVD technology - ultra-low pressure (ULP) and chemical vapor deposition (CVD), which to date has taken the entire global market Unique.
In addition to TiAlN as the primary coating, the new indexable insert also uses carbon nitride (TiN): it is both a tie layer between the cemented carbide substrate and the main TiAlN coating, and is also a facing on the primary coating. Is a bright spot in the new generation of cutting tool material TiN One of the most welcome surprises is that it is easier to identify tool wear than a black or gray finish.
The new coating method can also reduce the formation rate of hair crack, and the CVD coating with tensile stress is greatly reduced by the ability of the new coating to cause the larger wear resistance and better resistance to plastic deformation. Layer is not the same (which is a common ground before the industry), Wolfgang Vötsch said, Tiger • tec Gold TiAlN is the use of CVD process to produce the first to withstand compressive residual stress coating.
In addition, the new coating process is suitable for dry processing and wet processing. 'Dry machining there are other advantages: because the temperature change is small, the tool to bear the stress is small, so it is very environmentally friendly, coolant cost is very low, tool life very long. '
In short, Tiger • tec Gold is the most attractive place for 'processing reliability is good, tool life is long.' In my opinion, Walter achieved a huge leap.
In addition to Tiger • tec Gold WKP35G material, Walter also introduced more new generation of cutting tool material. Wolfgang Vötsch said that by the beginning of 2018, the entire millable indexable blade series will be used with Tiger • tec Gold WKP35G material.
For more information and machining examples, please visit www.tigertec-gold.walter.
Image: Walter BLAXX M3024
Illustration: Walter BLAXX M3024 Hexagon cutter used Tiger • tecGold. As expected, the test results show that the improvements in the three areas are particularly evident, which is also confirmed in practice: due to the flank The wear resistance is particularly good, the formation of hair crack speed is slow, resistance to plastic deformation of the strong, with WKP35G coating tool performance is very good. Photo: Walter
Photo: Walter BLAXX F5041 square shoulder cutter
Illustration: Tiger • tec Gold's Walter BLAXX F5041 square shoulder cutter is particularly attractive that the initial field test results show that the total tool life is extended by an average of 80%, but today's market has an average reporting performance increase of 100% 200%. Photo: Walter Company
Image: Tiger • tec Gold WKP35G coating
Caption: In addition to TiAlN as the primary coating, the new indexable insert is also made of carbon nitride (TiN): a material that is fairly hard and very corrosion resistant, both as a Connecting layer, but also the main coating on the surface. Photo: Walter company
To go to the Walter website: www.walter-tools.com
Visit Walter's website at www.walter-tools.com