In order to protect the environment, reduce energy consumption, and meet the urgent needs of high speed, high efficiency, high hardness, high precision and dry cutting, Sumitomo Electric Hardmetal Tools Co., Ltd. uses advanced nanotechnology, independently developed PVD coating technology and super Hard material technology, developed super ZX coated carbide tool for high speed dry cutting, SUMIBO-RON-BNC100/BNCl60 cubic boron nitride tool for high speed cutting and high precision cutting hardened steel, high speed SUMIBORON precision standard mold end mill for cutting molds. The profiles are as follows. 
First, super ZX coated carbide tool (1) Scope of application Super ZX coating has excellent heat resistance (oxidation resistance) and high temperature wear resistance, suitable for high speed dry milling of steel, stainless steel, cast iron, etc. , is an advanced coating new technology. 
(2) Coating characteristics Super ZX coating is a new technology of PVD using nanotechnology and independent research and development. Each layer of nano-sized TiAlN and AlCrN ultra-thin coatings are alternately laminated to form an ultra-multilayer coating of about 1000 layers. Floor.
The physical properties of the Super ZX coating and the original coating are shown in Table 1. The hardness of the coating was measured by the nanoindentation method, and the measured load of 19.6 mN was applied to the oblique section of the coating. The hardness of the original coating was 40 GPa, while the hardness of the super ZX coating was about 40% higher. It reaches 56 GPa; the residual compressive stress is measured according to the sin2Φ method, and the infiltration thickness is adjusted to a certain depth, and is measured on a BLl6XU large-scale radiation device. It can be seen from the results that the stress level in the coating increases from the substrate to the surface, and the compressive stress is the largest at 2.3 μm from the surface, reaching 2.7 GPa. The change in stress in the depth direction is adjusted according to the formation of the coating. As a result of the conditions; the average residual compressive stress in the coating also reached 1.9 GPa, which was 1.2 GPa larger than the original coating. The oxidation characteristics of the coating were evaluated by TG-DTA (Thermal Weight Measurement Differential Thermal Analysis) method.
Table 1 physical properties of coatings 〖HTSS〗
Name coating structure nanoindentation hardness initial oxidation temperature residual stress AE scratch test [°C] [GPa] [N]
Original coating TiN/AIN 40 816 0.7 73.8
Super ZX Coating TiAIN/AICrN 56 1029 1.9 76.7
As can be seen from Table 1, the initial oxidation temperature of the super ZX coating was increased by about 200 ° C compared to the original coating. After observing the surface of the sample which was slowly cooled in air at 950 ° C for 30 min, the oxidation of the original coated blade was very significant and had reached the blade base material; while the appearance of the super ZX coated blade remained pre-tested and oxidized. The outermost surface of the coating stops. The bond strength of the coating was determined by a scratch test using an acoustic emission (AE) scratch test under the critical weight of the peeling of the coating. From the test results, the bonding strength of the super ZX coating is almost the same as that of the original coating, only slightly higher, on the premise that the hardness and residual stress of the coating are high. 
(3) Cutting performance 1Applicable tool material
The 300 tool material is suitable for a wide range of workpiece materials from steel to stainless steel; the ACK300 is a new material for milling cast iron. 
Cutting performance of 2WEX type waveform edge milling cutter The tool material ACP200/300 and ACK300 with the super ZX coating have been customized for WEX type wave edge milling cutter. The WEX300 undulating edge milling cutter is a cutting-edge interchangeable high-efficiency end mill with high-quality machined surface and high reliability for finishing.
Table 2 Technical specifications and physical properties of BNCl00 and BNCl60
Use material coating CBN sintered body physical properties Type thickness CBN content CBN particle size bond hardness [HV] Bending strength TRS
High-speed cutting BNC100 TiMN+ 2μm 40-45% (volume) 1μm TiN 29- 1.05-
TiCN  32Gpa 1.15Gpa
High-precision cutting BNC160 TiMN+ 2μm 60-65% (volume) 3μm TiN 31- 1.10-
TiCN 33Gpa 1.20Gpa
Table 3 Specifications of BNCl00 and BNCl60
Material tip treatment chamfer angle [°] chamfer width [mm] rounding BNC100 standard type 25 0.12 with LS type 15 0.11
BNC160 Standard type 25 0.12 Yes LS type 20 0.10 Yes HS type 30 0.17 Yes
In the processing example (a), after machining three workpieces with other company PVD material tools, the tool damage is large, and the tool is broken when the fourth workpiece is machined. After machining four workpieces with the ACP200 material tool, the tool is cut. The damage is small and the tool life is increased. In the processing example (b), compared with other companies' PVD tool, the ACP200 tool has a small cutting sound and good condition. Even if the cutting conditions are improved by about 2 times, stable cutting can be achieved, and the surface quality is good. Smooth processing surface. 
It can be seen that compared with the TiAlN coated tools commonly used in the current processing, the life of the super ZX coated tool can be more than doubled, and the blade wear resistance (ie, the reliability of the tool) can be improved, so that it can bear high speed, Efficient machining. 
Second, high-speed, high-precision force hardened steel with SUMIBORON-BNC100/BNC160
(1) Scope of application BCNl00 has excellent wear resistance even at a cutting speed of 300m/min, and can be used for high-speed machining of hardened steel; BNCl60 is suitable for grinding only in the past, with dimensional accuracy up to IT6, surface High-precision machining of hardened steel with roughness Rz=1.6μm. 
(2) Tool characteristics The technical specifications and physical characteristics of BNCl00 and BNG160 blades are shown in Table 2. BNC100 and BNC160 are based on CBN with excellent heat resistance, abrasion resistance and chipping resistance. The special ceramic coating with TiAlN and TiCN as the main components is coated on it, which has excellent resistance. Abrasive and stable surface roughness. The technical specifications of the tool tip are shown in Table 3. By properly matching a standard tool tip, an LS-type tool tip that emphasizes cutting performance, and a high-strength HS-type tool tip, the cutting performance of the new material can be maximized in various machining operations. 
(3) Cutting performance The cutting performance of the BNC100 is superior to that of the BNX10 and BNC150 originally used for high-speed machining. The BNC100 has excellent wear resistance and chipping resistance, and exhibits longer tool life in high-speed machining. 
The cutting performance of BNCl60 is superior to that of BNC80 originally used for high-precision machining. BNCl60 has excellent wear resistance and a surface roughness of up to 2 μm. Compared with the BNC80, the BNC160 has excellent wear resistance, small diameter change, and stable IT6 machining accuracy. 
Third, high-speed, high-precision machining mold SUMIBORON precision end mill (1) Scope of application With the high speed of the machining center spindle, mold efficient processing technology is developing rapidly. In the past, high-speed steel end mills used to be the mainstream tool for mold processing. When the maximum speed of the machine spindle exceeds 10,000 revolutions per minute, the coated carbide end mill becomes the mainstream tool for mold processing. Now, the maximum speed of the spindle of the machining center has reached 40,000-60,000 rpm, and it is expected that the CBN end mill will become the mainstream tool. Compared with coated carbide end mills, CBN end mills have an overwhelming advantage in terms of tool life and surface quality. Because CBN has good heat transfer, it can suppress the increase of cutting temperature, and can perform high-speed cutting under spray cooling lubrication and dry cutting conditions, so it also has obvious advantages in protecting the environment. In order to meet the needs of high-speed cutting of molds, Sumitomo Electric Hardmetal Tools Co., Ltd. developed a small diameter CBN ball end mill BNBP mold finishing cutter, which is a R0.2-1.0mm long neck ball head. End mill for deep cavity machining. 
(2) Tool characteristics It is well known that compared with cemented carbide and high-speed steel, CBN has higher hardness and thermal conductivity, which is suitable for the cutting of high-hardness steel, but due to its poor toughness, it is used under the action of intermittent cutting load. The tip is easy to chip. In order to improve the chipping resistance of the BNBP mold finishing cutter, the SLIMIBORON new material with a large increase in the strength of the CBN sintered body and the optimized combination of the -40° large negative rake angle are used to significantly improve the chipping resistance. (similar to cemented carbide). Therefore, the BNBP mold finishing cutter can achieve high-precision machining that is stable to high-hardness molds. 
(3) Cutting performance When the button type die for mobile phones is cut by the R0.3 ball end mill at the machining center, the change in the wear width of the tool is the first step of the coated carbide tip end mill. After the mold, the tool wear begins to increase. When the second mold is finished, the tool wear width exceeds 0.03 mm, the burr appears on the mold, and the tool reaches the service life. After the initial wear of the CBN ball end mill, the wear width is almost There is no increase in the processing conditions of Table 4, no burrs are produced on the machined surface after processing 6 molds, no crushing defects appear, the machined surface remains good, and the tool can continue to be processed. Although dry milling is possible, spray cooling milling is recommended to extend tool life.
Table 4 Processing conditions Tool specification speed (r/min) Feed rate (mm/min) ap (mm) pp (mm)
R1.0 36000 3000 0.03 0.25
R0.5 40000 3000 0.02 0.02
R3.0 40000 1000 0.01 0.01
The total processing time of the powder metallurgy high speed steel (HRC63) bevel gear mold was processed by CBN ball end mill at the machining center for 2 hours and 28 minutes). For high-hardness materials such as powder high-speed steel, if rough machining is performed with coated carbide tools, the tool wear will be accelerated and increased, resulting in a rough machined surface, which cannot be removed on rough surfaces during semi-finishing and finishing. The unevenness of the mold is not guaranteed. If CBN tools are used from roughing, high-precision molds can be produced. 
Compared with coated carbide end mills, CBN end mills have overwhelming advantages in wear resistance, can process high hardness and high precision molds under high speed conditions, can greatly improve processing efficiency, and at the same time obtain high quality processing. The surface can greatly shorten the subsequent grinding time, enabling high-performance, high-hardness powder high-speed steel to achieve efficient processing. 
In summary, high-speed dry milling of steel, stainless steel, cast iron, etc. can be achieved using Super ZX coated tools; high-speed machining and high-precision cutting of hardened steel can be achieved using SUMIBORON BNC100/BNC160 and precision die end mills. Processing. The application of these new technologies and new products can reduce power consumption, reduce industrial pollution, and contribute to energy saving, environmental protection and production cost reduction.
First, super ZX coated carbide tool (1) Scope of application Super ZX coating has excellent heat resistance (oxidation resistance) and high temperature wear resistance, suitable for high speed dry milling of steel, stainless steel, cast iron, etc. , is an advanced coating new technology. 
(2) Coating characteristics Super ZX coating is a new technology of PVD using nanotechnology and independent research and development. Each layer of nano-sized TiAlN and AlCrN ultra-thin coatings are alternately laminated to form an ultra-multilayer coating of about 1000 layers. Floor.
The physical properties of the Super ZX coating and the original coating are shown in Table 1. The hardness of the coating was measured by the nanoindentation method, and the measured load of 19.6 mN was applied to the oblique section of the coating. The hardness of the original coating was 40 GPa, while the hardness of the super ZX coating was about 40% higher. It reaches 56 GPa; the residual compressive stress is measured according to the sin2Φ method, and the infiltration thickness is adjusted to a certain depth, and is measured on a BLl6XU large-scale radiation device. It can be seen from the results that the stress level in the coating increases from the substrate to the surface, and the compressive stress is the largest at 2.3 μm from the surface, reaching 2.7 GPa. The change in stress in the depth direction is adjusted according to the formation of the coating. As a result of the conditions; the average residual compressive stress in the coating also reached 1.9 GPa, which was 1.2 GPa larger than the original coating. The oxidation characteristics of the coating were evaluated by TG-DTA (Thermal Weight Measurement Differential Thermal Analysis) method.
Table 1 physical properties of coatings 〖HTSS〗
Name coating structure nanoindentation hardness initial oxidation temperature residual stress AE scratch test [°C] [GPa] [N]
Original coating TiN/AIN 40 816 0.7 73.8
Super ZX Coating TiAIN/AICrN 56 1029 1.9 76.7
As can be seen from Table 1, the initial oxidation temperature of the super ZX coating was increased by about 200 ° C compared to the original coating. After observing the surface of the sample which was slowly cooled in air at 950 ° C for 30 min, the oxidation of the original coated blade was very significant and had reached the blade base material; while the appearance of the super ZX coated blade remained pre-tested and oxidized. The outermost surface of the coating stops. The bond strength of the coating was determined by a scratch test using an acoustic emission (AE) scratch test under the critical weight of the peeling of the coating. From the test results, the bonding strength of the super ZX coating is almost the same as that of the original coating, only slightly higher, on the premise that the hardness and residual stress of the coating are high. 
(3) Cutting performance 1Applicable tool material
The 300 tool material is suitable for a wide range of workpiece materials from steel to stainless steel; the ACK300 is a new material for milling cast iron. 
Cutting performance of 2WEX type waveform edge milling cutter The tool material ACP200/300 and ACK300 with the super ZX coating have been customized for WEX type wave edge milling cutter. The WEX300 undulating edge milling cutter is a cutting-edge interchangeable high-efficiency end mill with high-quality machined surface and high reliability for finishing.
Table 2 Technical specifications and physical properties of BNCl00 and BNCl60
Use material coating CBN sintered body physical properties Type thickness CBN content CBN particle size bond hardness [HV] Bending strength TRS
High-speed cutting BNC100 TiMN+ 2μm 40-45% (volume) 1μm TiN 29- 1.05-
TiCN  32Gpa 1.15Gpa
High-precision cutting BNC160 TiMN+ 2μm 60-65% (volume) 3μm TiN 31- 1.10-
TiCN 33Gpa 1.20Gpa
Table 3 Specifications of BNCl00 and BNCl60
Material tip treatment chamfer angle [°] chamfer width [mm] rounding BNC100 standard type 25 0.12 with LS type 15 0.11
BNC160 Standard type 25 0.12 Yes LS type 20 0.10 Yes HS type 30 0.17 Yes
In the processing example (a), after machining three workpieces with other company PVD material tools, the tool damage is large, and the tool is broken when the fourth workpiece is machined. After machining four workpieces with the ACP200 material tool, the tool is cut. The damage is small and the tool life is increased. In the processing example (b), compared with other companies' PVD tool, the ACP200 tool has a small cutting sound and good condition. Even if the cutting conditions are improved by about 2 times, stable cutting can be achieved, and the surface quality is good. Smooth processing surface. 
It can be seen that compared with the TiAlN coated tools commonly used in the current processing, the life of the super ZX coated tool can be more than doubled, and the blade wear resistance (ie, the reliability of the tool) can be improved, so that it can bear high speed, Efficient machining. 
Second, high-speed, high-precision force hardened steel with SUMIBORON-BNC100/BNC160
(1) Scope of application BCNl00 has excellent wear resistance even at a cutting speed of 300m/min, and can be used for high-speed machining of hardened steel; BNCl60 is suitable for grinding only in the past, with dimensional accuracy up to IT6, surface High-precision machining of hardened steel with roughness Rz=1.6μm. 
(2) Tool characteristics The technical specifications and physical characteristics of BNCl00 and BNG160 blades are shown in Table 2. BNC100 and BNC160 are based on CBN with excellent heat resistance, abrasion resistance and chipping resistance. The special ceramic coating with TiAlN and TiCN as the main components is coated on it, which has excellent resistance. Abrasive and stable surface roughness. The technical specifications of the tool tip are shown in Table 3. By properly matching a standard tool tip, an LS-type tool tip that emphasizes cutting performance, and a high-strength HS-type tool tip, the cutting performance of the new material can be maximized in various machining operations. 
(3) Cutting performance The cutting performance of the BNC100 is superior to that of the BNX10 and BNC150 originally used for high-speed machining. The BNC100 has excellent wear resistance and chipping resistance, and exhibits longer tool life in high-speed machining. 
The cutting performance of BNCl60 is superior to that of BNC80 originally used for high-precision machining. BNCl60 has excellent wear resistance and a surface roughness of up to 2 μm. Compared with the BNC80, the BNC160 has excellent wear resistance, small diameter change, and stable IT6 machining accuracy. 
Third, high-speed, high-precision machining mold SUMIBORON precision end mill (1) Scope of application With the high speed of the machining center spindle, mold efficient processing technology is developing rapidly. In the past, high-speed steel end mills used to be the mainstream tool for mold processing. When the maximum speed of the machine spindle exceeds 10,000 revolutions per minute, the coated carbide end mill becomes the mainstream tool for mold processing. Now, the maximum speed of the spindle of the machining center has reached 40,000-60,000 rpm, and it is expected that the CBN end mill will become the mainstream tool. Compared with coated carbide end mills, CBN end mills have an overwhelming advantage in terms of tool life and surface quality. Because CBN has good heat transfer, it can suppress the increase of cutting temperature, and can perform high-speed cutting under spray cooling lubrication and dry cutting conditions, so it also has obvious advantages in protecting the environment. In order to meet the needs of high-speed cutting of molds, Sumitomo Electric Hardmetal Tools Co., Ltd. developed a small diameter CBN ball end mill BNBP mold finishing cutter, which is a R0.2-1.0mm long neck ball head. End mill for deep cavity machining. 
(2) Tool characteristics It is well known that compared with cemented carbide and high-speed steel, CBN has higher hardness and thermal conductivity, which is suitable for the cutting of high-hardness steel, but due to its poor toughness, it is used under the action of intermittent cutting load. The tip is easy to chip. In order to improve the chipping resistance of the BNBP mold finishing cutter, the SLIMIBORON new material with a large increase in the strength of the CBN sintered body and the optimized combination of the -40° large negative rake angle are used to significantly improve the chipping resistance. (similar to cemented carbide). Therefore, the BNBP mold finishing cutter can achieve high-precision machining that is stable to high-hardness molds. 
(3) Cutting performance When the button type die for mobile phones is cut by the R0.3 ball end mill at the machining center, the change in the wear width of the tool is the first step of the coated carbide tip end mill. After the mold, the tool wear begins to increase. When the second mold is finished, the tool wear width exceeds 0.03 mm, the burr appears on the mold, and the tool reaches the service life. After the initial wear of the CBN ball end mill, the wear width is almost There is no increase in the processing conditions of Table 4, no burrs are produced on the machined surface after processing 6 molds, no crushing defects appear, the machined surface remains good, and the tool can continue to be processed. Although dry milling is possible, spray cooling milling is recommended to extend tool life.
Table 4 Processing conditions Tool specification speed (r/min) Feed rate (mm/min) ap (mm) pp (mm)
R1.0 36000 3000 0.03 0.25
R0.5 40000 3000 0.02 0.02
R3.0 40000 1000 0.01 0.01
The total processing time of the powder metallurgy high speed steel (HRC63) bevel gear mold was processed by CBN ball end mill at the machining center for 2 hours and 28 minutes). For high-hardness materials such as powder high-speed steel, if rough machining is performed with coated carbide tools, the tool wear will be accelerated and increased, resulting in a rough machined surface, which cannot be removed on rough surfaces during semi-finishing and finishing. The unevenness of the mold is not guaranteed. If CBN tools are used from roughing, high-precision molds can be produced. 
Compared with coated carbide end mills, CBN end mills have overwhelming advantages in wear resistance, can process high hardness and high precision molds under high speed conditions, can greatly improve processing efficiency, and at the same time obtain high quality processing. The surface can greatly shorten the subsequent grinding time, enabling high-performance, high-hardness powder high-speed steel to achieve efficient processing. 
In summary, high-speed dry milling of steel, stainless steel, cast iron, etc. can be achieved using Super ZX coated tools; high-speed machining and high-precision cutting of hardened steel can be achieved using SUMIBORON BNC100/BNC160 and precision die end mills. Processing. The application of these new technologies and new products can reduce power consumption, reduce industrial pollution, and contribute to energy saving, environmental protection and production cost reduction.
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