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Case studies for cutting tool coatings

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Milling of titanium alloy

Titanium alloys are frequently used in aerospace applications. For an OEM aerospace customer looking to mill a titanium alloy under lubricated conditions with a ball nose end mill, we are looking for a coating that helps reduce the difficulty machining titanium. The intended machining process has a cutting speed of 135 m per minute, an axial depth of 0.4 mm and a radial depth of 0.2 mm.

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Milling of SUS360 stainless steel

An aerospace customer is searching for the best coating to support milling of SUS360 steel with a 20 mm diameter end mill with 4 flutes. Cutting speed is 120 m per minute, under wet conditions.

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Milling of stainless steel with end mill

An OEM customer is looking for a coating to improve the 8 mm square cemented carbide end mill used to mill 1.4122 stainless steel. The milling process uses coolant, at a tool rotation speed of 8000 rpm and a cutting speed of 201 m/min. Axial depth is 8 mm and radial depth 0.4 mm.

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Milling of aluminum 2024

The challenge is determining the right coating for an OEM customer looking to mill Al 2024 with a 12 mm cemented carbide with minimum quantity lubrication. Rotation speed is 12000 to 20000 turns per minute, feed speed is 1397 to 2565 mm per minute.

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Milling of acrylate and acetate

For an OEM eyeglasses manufacturer, we are looking to select a coating that supports milling of acrylate and acetate with an end mill ø 4.0*72 mm.

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Insert milling of hard steel

Finding the right coating for an OEM customer machining 1.2379 steel with an HRC of 62. The cutting speed of the process is 160 m per minute. Cutting length is 141 m. Other process parameters: feed per tooth is 0.25 mm, axial depth is 0.22 mm and radial depth is 0.3 mm.

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Dry milling of HRC die

An OEM customer is looking for the right coating to enhance dry milling of SKD11 tool steel (HRC 60-62) with a square end mill (Ø8 mm). The milling process uses a 4000 rpm tool rotation speed, cutting speed of 100 m per minute, a radial depth of 0.25 mm and an axial depth of 8 mm.

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Dry continuous turning of a gray cast iron

For an OEM customer looking to machine gray cast iron (GG250) with CNMG 120408 inserts, we are looking for the best coating. The dry continuous turning process has a cutting speed of 400 m per minute, a feed of 0.35 mm per revolution and an axial depth of 2.0 mm. The main issue with gray cast iron is its low impact strength, leading to brittle behavior and abrasive wear. In most other respects, machinability is very good.

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Drilling of compacted graphite iron

CGI is a material that can meet the increasing demands for high strength and reduced weight while still retaining reasonable machinability.

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Drilling of AlSi12

The problem faced is very abrasive material.

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Continuous external turning of steel

Finding the right coating for an OEM machining 1.6582 steel with CNMG inserts. The steel has an HRC of 28. The machining process uses a cutting speed of 210 m/min, a feed of 0.3 mm per revolution and an axial depth of 2.5mm.

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Gear cutting of steel

Determining the right coating for an automotive end user looking to machine 1.7131 steel (30-35 HRC) with a solid MC90 intermet hob. The machining process takes place under dry conditions, at a speed of 230m/min.

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Discuss your challenges with Kalpak Shaha

Dr. Kalpak Shaha, Global Segment Manager Cutting Tools, will be glad to support you.

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