Cutting materials, tools and coolants

for machining with geometrically

defined cutting edges part 1
Manufacturing Technology I
Lecture 4

Laboratory for Machine Tools and Production Engineering

Chair of Manufacturing Technology

Prof. Dr.-Ing. Dr.-Ing. E.h. F. Klocke

WZL/Fraunhofer IPT

Contents of the lectures 4 and 5

Lecture 4

tool steels

cemented carbides

coatings

Lecture 5

ceramics

tool design

cooling lubricants

WZL/Fraunhofer IPT

Seite 1

Structure

Introduction
classification according to hardness and toughness
nomenclature and classification of cutting materials

Tool steels
Cemented carbides
Coatings
Summary

WZL/Fraunhofer IPT

Seite 2

Main requirements on tool materials

Hardness
Abrasion

Toughness
Heavy cuts ( high feed values and depth of cut, high
cutting forces)
Interrupted cuts
High dynamics

Heat resistance
Diffusion
High cutting speed (heat generation)
Heat shock resistance

WZL/Fraunhofer IPT

Seite 3

at
er
ia
l
m

BN

cu
tti
ng

DP

Al2O3 ceramic

Al2O3 +
TiC

im
al

op
t

Cutting speed,
Wear resistance, thermal resistance

Classification of cutting materials

coated
Cermet

Si3N4ceramic

Cermet

Coated
cemented
carbide

cemented carbide based

on tungsten carbide
DP: 1 in consideration of hardness
2 in consideration of hardness
and temperature

fine and
ultra fine grain
cemented
carbide
coated HSS
HSS

toughness, flexural strength and feed

WZL/Fraunhofer IPT

Seite 4

Classification of cutting materials

cutting materials for processing
with geometrically defined cutting edge

cold working steel

tool steel
high speed steel

cemented carbides

WC-Co
WC-(Ti,Ta,Nb)C-Co
TiC/TiN - Co,Ni
oxide ceramic

ceramics

super hard cutting

materials

WZL/Fraunhofer IPT

composite ceramics
silicium-nitride ceramic
boron nitride
diamond
Seite 5

Application Groups

P Group

WC-(Ti,Ta,Nb)C-Co
high heat resistance, reduced toughness

M Group
K Group

WZL/Fraunhofer IPT

(WC, Co)
high toughness, reduced heat resistance

Seite 6

Classification and application of hard cutting materials (DIN ISO 513)

cemented carbides
denotation

1)

cemented carbide group

HW

uncoated cemented carbide, main content

tungsten-carbide (WC) with grain size 1 m

HF

uncoated cemented carbide, main content

tungsten-carbide (WC) with grain size < 1 m

HT 1)

uncoated cemented carbide, main content

titanium carbide (TiC) or titanium nitride (TiN) or both

HC

cemented carbide as above, coated

these cemented carbides are also called "Cermets"

WZL/Fraunhofer IPT

Seite 7

Classification and application of hard cutting materials (DIN ISO 513)

ceramic
denotation

group of ceramic

CA

oxide ceramic,
major content aluminum
oxide (Al2O3)

CM

composite ceramic, major

content oxide ceramic
(Al2O3), also non-oxide
ceramic

CN

nitride ceramic,
major content silicon
nitride (Si3N4)

CR

oxide ceramic,
major content aluminum
oxide (Al2O3)
reinforced

CC

oxide ceramic as above,

but coated

WZL/Fraunhofer IPT

boron nitride

diamond
denotation

diamond group

DP

poly-crystalline
diamond

DM

mono-crystalline
diamond

denotation

BL

BH

BC

boron nitride group

cubic-crystalline
boron nitride with low
content of boron
nitride
cubic-crystalline
boron nitride with
high content of boron
nitride
cubic-crystalline
boron nitride as
above, but coated

Seite 8

Application of cutting materials (DIN ISO 513)

machining main group (Source: DIN ISO 513)
denotation

color

blue

work piece material

steel:
all kinds of steel and cast steel,
except rustproof steel with
austenitic microstructure

yellow

stainless steel:
stainless austenitic and austenitic-ferritic
steel and cast steel

red

cast iron:
cast iron with flake graphite, cast iron with
spherical graphite, annealed cast iron

application group
hard cutting materials
P01
P10
P20
P30
P40
P50
M01
M10
M20
M30
M40
K01
K10
K20
K30
K40

increasing wear resistance of the cutting material, increased cutting speeds possible

increasing toughness of the cutting material, increased feed rates possible

WZL/Fraunhofer IPT

P05
P15
P25
P35
P45

M05
M15
M25
M35

K05
K15
K25
K35

Seite 9

Application of cutting materials (DIN ISO 513)

machining main group (Source: DIN ISO 513)
denotation

color

work piece material

green

non-ferrous metal:
aluminum and other non-ferrous metals,
non-metal work materials

brown

special alloys and titanium:

high-temperature special alloys based upon
iron, nickel and cobalt, titanium and titanium
alloys

grey

hard work materials:

hardened steel, hardened cast iron materials,
chilled cast iron

application group
hard cutting materials
N01
N10
N20
N30
S01
S10
S20
S30
H01
H10
H20
H30

increasing wear resistance of the cutting material, increased cutting speeds possible

increasing toughness of the cutting material, increased feed rates possible

WZL/Fraunhofer IPT

N05
N15
N25
S05
S15
S25
H05
H15
H25

Seite 10

10

Structure
Introduction

Tool steels
unalloyed tool steels
alloyed tool steels
high speed steel (HS)

Cemented carbides
Coatings
Summary
WZL/Fraunhofer IPT

Seite 11

11

Main design features of tool steels

Ordinary tool steels

Matrix: Martensite, primary carbides

High speed steel

Matrix: Martensite, primary carbides, secondary carbides

WZL/Fraunhofer IPT

Seite 12

12

Examples of unalloyed cold working steels

unalloyed cold working steel
denotation
Nr.

composition [%]

C85W
1.1830

Si
0,15
0,40
0,25
0,40

Mn
0,60
0,80
0,50
0,70

C125W
1.1563

1,20
1,35

0,10
0,30

0,10
0,35

45CrMoV7
1.2328
115CrV3
1.2210

0,42
0,47
1,10
1,25

0,20
0,30
0,15
0,30

0,85
1,0
0,20
0,40

1,7
1,9
0,5
0,8

0,25
0,30
-

0,05
0,07
0,12

X210CrW12
1.2436

2,0
2,25

0,10
0,40

0,15
0,45

11,0
12,0

C45W
1.1730

Cr

Mo

application

C
0,40
0,50
0,80
0,90

W
hammer, axe, shear, screw
driver, chisel
wood saw, hand saw, solid of
composite saw blades
file, scraper, paper shear

alloyed cold working steel

WZL/Fraunhofer IPT

all kind of chisels

file, scraper, paper shear
0,6
0,8

cutting tools, shear for steel

cutting, broaching tools

Seite 13

13

Variations and applications of high speed steels

composition

W - Mo - V - Co
I

18% W

HS18-0-1
HS18-1-2- 5
HS12-1- 4 - 5

II

12% W

III

6% W
+ 5% Mo

HS10-4- 3 - 10
HS6-5-2
HS6-5- 3
HS6-5-2- 5
HS2-9-1

IV

2% W
+ 9% Mo

HS2-9-2
HS2-10-1-8

WZL/Fraunhofer IPT

cutting steel at

denotation

medium load

maximum load

< 850 N/mm2

> 850 N/mm2

roughing

finishing

+
-

(+)
(+)

+
+

+
-

(+)
+

+
-

+
-

+
-

Seite 14

High-speed steels are notated with the letters HS and the indication of the percental
amount of alloying additions in the sequence W-Mo-V-Co, e.g. HS10-4-3-10.
The classification of high-speed steels is raised by their W- and Mo-concentraion into
four alloy- and performance groups.

14

Main applications of the most important high speed steels

steel group
materdenotation according to
ial
DIN EN ISO 4957
Nr.

application

HS6-5-2

1.3343

standard material for roughing and finishing, twist drills, tapping tools,
milling tools, broaching tools, reaming tools, countersinker, hobbing tools,
saws, forming tools

HS6-5-3

1.3344

high performance tapping and reaming tools, high performance milling

tools, broaching tools, twist drills

HS6-5-2-5

1.3243

high performance milling tools, turning and hobbing tools, high performance
twist drills and tapping tools, cold working tools, roughing tools with high
tenacity

HS10-4-3-10

1.3207

universal roughing and finishing tools, turning and high performance milling
tools, free cutting steel, tools for wood machining

HS2-9-2

1.3348

twist drill and tapping tools, milling tool, reaming tool, broaching tool

HS2-9-1-8

1.3247

end milling tools, turning tools for free cutting operations, twist drills,
tapping tools

WZL/Fraunhofer IPT

Seite 15

15

Production of high speed steel by melting

HS18-1-2-5

denotation

HS10-4-3-10

HS12-1-4-5 HS12-1-4

HS6-5-2

hardening temperature C

1280

1240

1240

1240

1230

annealing at 0,5 1 h

3
560 C

2 570 C
1 550 C

2
570 C

2
560 C

2
540 C

1600

1000
800
600
400
200

block
annealing

block turning

1200
melting and founding

temperature T / C

1400

forging

rolling

final annealing

0
time t / h
WZL/Fraunhofer IPT

Seite 16

16

en
ize
au
st

annealing

A
F
heating in
air
B vacuum furnace

air

air

3.
an
ne
al
in
g

annealing time in each case: 1 2 h

2.
an
ne
al
in
g

oil / air

1.
an
ne
al
in
g

compensating temperature

finishing

slow furnace
down cooling

pre machining

temperature T / C

st

re
ss

he
at
in
g

re
lie
fa
nn
ea
lin
g

Heat treatement of high speed steel

air

time t / h
A 600 - 650 C
B 1. pre-heating stage ca. 400 C (in salt bath)
C 2. pre-heating stage 850 C
WZL/Fraunhofer IPT

D
E
F
G

3. pre-heating stage 1050 C

hardening temperature ~1200 C
salt bath 500 - 600 C
50-80C
Seite 17

To realize their endhardness HSS-Tools are preapared by a heattreatment. In a first step

they are hardend ( heated, held on austenite temperature and cooled down with high
speed), afterwards several times tempered.

17

Temperature dependent effects on the hardness in tempering HS

M

~ 66

M2
S
A2
hardness / HRC

M1

A1

temper temperature T / C
WZL/Fraunhofer IPT

~ 600
Seite 18

Tempering of high-speed-steel takes place bei temperatures between 540 580 C and is
for this reason in the temperature range of secondary harndess. This pickup of hardness
leads under normal hardening- and temperconditons to hardness values, which can be
clearly higher then these after quenching.
The cutting material hardness resulting from the overlay of the different processes is
shown as a sum graph S depending on the tempering temperature.

18

Tools made of high speed steel - examples

broaching tools for
internal broaching
external broaching
hard broaching

source: Sandvik

tools for

source: PWS

tools for gear shaping

drilling
milling
tapping
thread milling
thread forming

cylinder gear
spline shaft
chain wheel
internal gear
source: Forst

WZL/Fraunhofer IPT

Seite 19

19

Structure
Introduction
Tool steel

Cemented carbide
WC-Co-based cemented carbide (HW)
TiN/TiC-based cemented carbide cermet (HT)
fine grain cemented carbide

Coatings
Summary
WZL/Fraunhofer IPT

Seite 20

20

Milestones in the development of cemented carbides

1927

Spring Fair Leipzig: 1. WC-Co-HM

Manufacturer Krupp, Denotation WIDIA

1928

Carboloy (General Electric)

1931

WC-TIC-Co cemented carbides

1934

TiC-Mo2 C-Ni (1. cermet-generation )

Manufacturer Plansee, denotation Titanit S

1937

Titanit (Plansee), Bhlerit (Bhler)

1942

Coromant (Sandvik)

68/69

presentation of coated cemented carbides

1970

fine grain

1973

Spinodal - Cermet ( 1. Cermet with TiN )

73/74

increased development of Cermets

1993

ultrafine and nanocrystalline grain

WZL/Fraunhofer IPT

hardness HV30
flexural strength N/mm2
( ) mean grain diameter m
standard (1,4 - 1,8)
fine grain (< 1)
ultra fine grain (< 0,5)

1000

2000

3000

4000
360%

100%

multi layer

patent for manufacturing of WC.Co-HM,

K. Schrter

uncoated

1923

tool life
Seite 21

21

Production process of cemented carbide components

WZL/Fraunhofer IPT

Seite 22

22

Influences on wear resistance and toughness of cemented carbides

WZL/Fraunhofer IPT

Seite 23

With regard to the wear- and performance abillity of uncoated and coated cemented
carbides the features of cemented carbide substrates play a key role

23

Microstructure of conventional cemented carbide and cermet

WZL/Fraunhofer IPT

Seite 24

In conventional cemented carbides based on WC the tungsten carbides mostly exist in

prism shape with a triangular base. The carbide skeleton is filled up with the binding
phase.
The structure of cermets is only made of chamfered mixed carbonitrides. Characteristicly
for their microstructure is the core-shell-structure of the hard material.

24

Composition and properties of conventional WC-Co cemented

carbides
cemented carbide classification
source: DIN ISO 513
sort

HW - K05

HW - K10

HW - K25

HW - K40

WC - 4Co

WC - 6Co

WC - 9Co

WC - 12Co

density / (g/cm-3)

source: ISO 3369

15,1

14,9

14,6

14,2

hardness HV 30

source: ISO 3878

1730

1580

1420

1290

compression strength
(cyl.-specimen) / (N/mm2)

source: ISO 4506

5700

5400

5000

4500

flexural strength / (N/mm2)

source: ISO 3327

1600

2000

2350

2450

Youngs Modulus / (103N/mm2)

source: ISO 3312

650

630

590

580

6,9

9,6

12,3

12,7

0,21

0,22

0,22

0,22

thermal conductivity / (Wm-1K-1)

80

80

70

65

thermal expansion coefficient

(293 K1073 K) / (10-6K-1)

5,0

5,5

5,6

5,9

fracture toughness /

(Nm1/2/mm2)

Poisson ratio

WZL/Fraunhofer IPT

Seite 25

Cemented carbides of this group exist almost completely out of hexagonal tungsten
monocarbide and the binding phase cobalt. They can contain up to 0,8 mass% VC and/or
CR3C2 and/or up to 2 mass% (TaNb)C as doping additives to controle the grain size and
constancy.

25

Microstructure of micro grain and sub micro grain cemented

carbides

micro grain
WC - 6-Co carbides

source: Krupp Widia

WZL/Fraunhofer IPT

14
min
tool life

(B): flexural strength N/mm2

(H): hardness HV30

standard

turning of chilled cast iron

( 80 shore )

10
8
6
4

sub micron

vc = 16 m/min
f = 0,1 mm
ap = 1,0 mm
insert:
SPGN 120308
sharp cornered,
= 75

2
0
standard

micro grain

sub micron
Seite 26

26

Dependency of grain size, hardness and toughness

4000
2400

flexural strength
N/mm

hardness
HV30

3000

2000
1800
1600

nano:

2500

ultra fine: 0,2 - 0,5 m

2000

super fine: 0,5 - 0,8 m

fine:

1400

1500

1200

1000

1000

< 200 nm

0,8 - 1,3 m

500
4

10

12

14

16

cobalt content / %
source: Widia
WZL/Fraunhofer IPT

Seite 27

27

Cutting edge after hard milling 55 HRC

conventional cemented carbide 9.5% Co

milling time 90 min

WZL/Fraunhofer IPT

ultra fine cemented carbide 7.5% Co

milling time 175 min

Seite 28

28

Application of ultra fine grain cemented carbide - micro milling

1 mm

work piece:
cutting speed:
revolutions:
feed per tooth:
depth of cut:
width of cut:

WZL/Fraunhofer IPT

X5CrNi18-10
6 m/min
8000 min-1
1 to 5 m
64 m
254 m

Seite 29

29

Composition and properties of WC-(Ti,Ta,Nb)C-Co cemented

carbides
cemented carbide classification
source: DIN ISO 513
composition (mass-%)
WC
(Ti, Ta, Nb)C
Co
density / (g/cm-3)
hardness HV 30
compression strength
(cyl.-specimen) / (N/mm2)
(N/mm2)

HW - P10 HW - P15 HW - P25 HW - P30 HW - M10 HW - M15

source: ISO 3369

60,0
31,0
9,0
10,6

64,5
25,5
10,0
11,7

72,7
17,3
10,0
12,6

78,5
10,0
11,5
13,0

84,5
9,5
6,0
13,1

82,5
11,0
6,5
13,3

source: ISO 3878

1560

1500

1490

1380

1700

1550

source: ISO 4506

4500

5200

4600

4450

5950

5500

2200

2250

1750

1900

source: ISO 3327

1700

2000

Youngs Modulus / (103N/mm2) source: ISO 3312

520

500

550

560

580

570

fracture toughness / (Nm1/2/mm2)

8,1

9,5

10,0

10,9

9,0

10,5

Poisson ratio

flexural strength /

0,22

0,23

0,22

0,23

0,22

0,22

thermal conductivity / (Wm-1K-1)

25

20

45

60

83

90

thermal expansion coefficient

(293 K1073 K) / (10-6K-1)

7,2

7,9

6,7

6,4

6,0

6,0

WZL/Fraunhofer IPT

Seite 30

Cemented carbides of this group contain besides tungsten mixed carbides (MC) out of
titanium- tantalum- niobium- and/or zirconiumcarbide. Compared to the WC-Cocemented carbides they show improved high temperature abbilities.

30

Composition and properties of Cermets

cermet group
source: DIN ISO 513
composition (mass-%)
carbon nitride
additional carbides
Co/Ni

HT P05

HT P10

HT P20

89,0
0,6
10,4

85,7
0,8
13,5

82,3
1,0
16,7

density / (g/cm-3)

source: ISO 3369

6,1

7,0

7,0

hardness HV 30

source: ISO 3878

1650

1600

1450

compression strength
(cyl.-specimen) / (N/mm2)

source: ISO 4506

5000

4700

4600

flexural strength / (N/mm2)

source: ISO 3327

2000

2300

2500

source: ISO 3312

(103N/mm2)

460

450

440

fracture toughness / (Nm1/2/mm2)

7,2

7,9

10,0

Poisson ratio

0,21

0,22

0,21

9,8

11,0

15,7

9,5

9,4

9,1

Youngs Modulus /

thermal conductivity /

(Wm-1K-1)

thermal expansion coefficient (293 K1073 K) /

(10-6K-1)

source: Pulvermetallurgie der Hartmetalle

WZL/Fraunhofer IPT

Seite 31

In comparison with conventional cemented carbides cermets show a lower density.

Significant differences compared to WC-based cemented carbides are the clearly lower
heat conductivity and at the same time higher thermal extension.

31

Turning of steel using cermets

WZL/Fraunhofer IPT

Seite 32

Due to the high edge strength, the high resistance against abrasive wear, and little
adhesive wear cermets are particularly suited for finishing steels.

32

Milling with Cermets

P
carbide K25

cutting speed vc

end mill,

end mill,

WZL/Fraunhofer IPT

Seite 33

33

Application of different cemented carbide qualities

WC-Co-carbide:
(K-group)

+ high hardness and wear resistance because of tungsten carbide

+ high edge toughness because of high solubility of WC in the
WC-Co binder
- reduced heat resistance because of diffusion

WC-(Ti,Ta,Nb)C-Co: + high heat resistance, resistance against oxidation and

(P-group)
diffusion because of high content of TiC, TaC and NbC
- reduced edge toughness because of poor solubility of carbides
in the binder

cermet (TiC/TiN) :

WZL/Fraunhofer IPT

+ high heat resistance, high resistance against oxidation

and diffusion
+ high surface quality because of low adhesion
- low toughness
- low thermal shock resistance
Seite 34

34

Structure
Introduction
Tool steel
Cemented carbide

Coatings
Chemical vapour deposition (CVD)
Physical vapour deposition (PVD)

Summary

WZL/Fraunhofer IPT

Seite 35

35

Wear phenomena on coated cutting tools

adheasion
delamination
abrasion
surface effects
oxidation
diffusion

stresses
fracture formation
outbreak

volume effects

break

WZL/Fraunhofer IPT

Seite 36

Primary task of the hard material layer is to prevent the contact between work material
and tool during machining in order to reduce the tool wear caused by adhesion, abrasion,
diffusion and oxidation at the surface of the cutting material.

36

Design of a CVD coating installation

coating furnace

CH

H2
gas entrance
H2

H2+
TiCl4

liquid
TiCl4

evaporator

WZL/Fraunhofer IPT

gas exit
Seite 37

To produce a TiC-layer for example Titantetrachlorid??? (TiCl4) is vaporized and let

together with methane to a reaction vessel which can hold a couple of thousands of
cutting inserts. Thereby the titaniumcarbide is produced in a chemical reaction at a
temperature between 900 C and 1100 C and a pressure below atmospheric pressure.

37

TTT-curve of a WC Co alloy at coating temperatures

1200
Co - 5 W - 0,23 C

temperature T / C

1000 HT-CVD
WC

Eta

Eta'

800 MT-CVD
Co3W
600

P-CVD
PVD

400

200
0,01

0,1

1,0

10

100

1000

time t / h
WZL/Fraunhofer IPT

Seite 38

Time-Temperature-Transformation chart of a cobalt aloy. Listed are typical coating

temperatures and times for the processes HAT-CVD, MT-CVD, PA-CVD and PVD.
The figure shows that in the classical HT-CVD and middle temperature-CVD-process the
area of eta-phase-precipitation is run through respectively affected.
Compared to that in low temperature processes like PA-CVD- and PVD-processes no
changes of constitution is to be expected.

38

Coating process and flexural strength

10
F

change of flexural strength / %

0
PA-CVD

2,6

-10
400C

14,5

-20
PVD
PVD
-30
CVD

PVD

-40

-50

TiN
TiN/Ti(C,N)

550C

PA-CVD

700C

PVD

1000C

PVD
CVD

-60
0
WZL/Fraunhofer IPT

4
6
8
coating thickness / m

10
Seite 39

The comparing examination of the bending strength of thin, differently coated WC-Co
cemented carbides shows which influence the coating temperature and layer thickness
have on this important paramater of toughness performance.

39

Coating method and cutting performance

100000

Arc-PVD

50000

MT-CVD
uncoated

impacts n

10000
5000

1000
work mat.: 42CrMo4+QT
Rm= 980 N/mm2
substrate: P30/40
SPUN 120312
f = 0,2 mm
ap = 2,5 mm

500

100
60
WZL/Fraunhofer IPT

80 100
200
300 400
cutting speed vc / (m/min)
Seite 40

The MT-CVD- as well as the PVD-coated cemented carbide are clearly superior in their
performance compard to the uncoated cemented carbide. Coming to lower cutting
speeds the PVD-layer shows advantages.

40

Commonly used layer structure

monolayer (thin hard layer)

t = 0.5 ... 50 m

super hard coatings

(CVD-DP / BN)

typical multi-layer with functional

Intermediate layers
t = 0.5 ... 10 m

hard and soft compounds

(MoS2 , WC/C, graphite etc..)

multilayer (nano-structure)
t = few atomic cells ... 100 nm

hard film + solid lubricant

film
(a-Me-C:H)

graded layer

WZL/Fraunhofer IPT

Seite 41

41

Increased tool life using Middle-Temperature-CVD-coatings

WZL/Fraunhofer IPT

Seite 42

42

Performance of Plasma-CVD coated cemented carbide

16
disk milling

12

work material: 60WCrV8,

220 HB

work travel lf / m

cutting material: HW-P25

vc = 80 m/min
fz = 0,08 mm
ae = 42 mm
ap = 6 mm

0
carbide P25 / TiN, PA-CVD - coated

none

HT-CVD

PA-CVD

type of coating

WZL/Fraunhofer IPT

Seite 43

The attributes of PA-CVD-coated cemented carbides have a positive affect on their

performance in machining higher-strength steel workmaterials in interupted cut.
The sensitivity of the composite against Kammrissbildung ??? and failure through
decomposotion is much smaller compared to HAT-CVD-coated cutting materials.

43

AlON

coating thickness

AlON
transient
coating
substrate

WZL/Fraunhofer IPT

100
%
80
70
60
40
30
20

6 m / 4 m

TiN

probability of tool breakage

TiN
AlON

source: Widia,
Sumitomo

CVD

4 m / 6 m

TiN

PVD
P-CVD

1 m / 9 m

3 m

AlON

wear
resistance

TiN

PVD
CVD

tenacity

Improved wear resistance and tenacity using multilayer coatings

CVD -coating
Al2O3 / TiC
total coating
thickness for all
tools 10 m

10
0
single layer thickness Al2O3 / TiC
Seite 44

With rising coat thickness the wear resistance of CVD-coated cemented carbides
increases, at the same time however the bending strength and therewith the toughness
decreases.

44

Increased fracture resistance using graded subsurfaces

multilayer coating

360%

multilayer
coating on
graded
subsurface

WZL/Fraunhofer IPT

graded
subsurface

workpiece: C25
vc
=
200 m/min
f
=
0,15 - 0,3 mm
ap
=
0,5 - 1,5 mm

100%
tool life
hardness
P 25

10 m

1000 1200 1400 1600

hardness HV
Seite 45

45

Improvement of edge stability using Ti(C,N)-transition layers

WZL/Fraunhofer IPT

Seite 46

46

CVD multilayer-coatings with Zr

SEM-picture

calotte crater

carbide

WZL/Fraunhofer IPT

Seite 47

47

C-based coatings
classification of C-based coatings based
on hydrogen-content and hardness
crystal lattice
of diamond
diamond

hardness

crystal lattice
of graphite

amorphous
carbon
(DLC)

graphite

plasmapoymer

hydrogen-content
WZL/Fraunhofer IPT

Seite 48

48

CVD-diamond thin-film coatings

micro-crystalline (standard) nano-crystalline (even)

multi-layer (even)

micro-crystalline
nano-crystalline

source: CemeCon
WZL/Fraunhofer IPT

Seite 49

49

Reduced adhesion and abrasion by smooth CVD-diamond coating

PVD-TiB2
lc = 40 m

CVD-diamond coated tool (coating thickness 4m)

lc = 40 m
New

900 m

rake face

900 m

5 m

severe adhesions

100 m
900 m

flank face

900 m

severe adhesions

900 m

HC-K20
end mill with two teeth
d = 10 mm
WZL/Fraunhofer IPT

slot milling
ap = 3 mm

vc = 200 m/min
fz = 0,15 mm
dry
Seite 50

50

Physical Vapour Deposition (PVD) coatings

~500C instead of 1000C (CVD)

limited chemical bonding with substrate

preservation of compressive stresses during the substrate grinding process

sharp edges

preservation of the toughness in the substrate material

HS coatable

lower layer thicknesses compared to CVD

WZL/Fraunhofer IPT

Seite 51

51

PVD-process vacuum plating

specimen holder,
bias voltage
water cooled
recipient

gas inlet
inert process gas
reaction gas

coating
plasma
and
reaction gas ions
metal ions

vacuum plating device

- electrical heating
or
- electron beam (EB-PVD)

electron beam (EB-PVD)

target material
evaporator

energy supply
vacuum pump
WZL/Fraunhofer IPT

Seite 52

Beim Vakuumverdampfen wird das Schichtmaterial in einem Tiegel im Hochvakuum

verdampft. Die Dampfatome weisen bei diesen Drcken mittlere freie Weglngen von
bis zu mehreren Metern auf. Sie treten deshalb i. Allg. nicht in Wechselwirkung
miteinander und gelangen geradlinig zum Substrat. Da dieses erheblich klter ist als der
Dampf, kondensieren die Teilchen auf dem Substrat. Aufgrund des geradlinigen
Teilchenflugs muss der Substratwerkstoff in der Beschichtungskammer bewegt werden,
um Abschattungseffekte und ungleichmige Schichtdicken zu vermeiden.

52

PVD-process sputtering
gas inlet
inert process gas
reaction gas

specimen holder,
bias voltage
sputter device

coating

electrode as
additional
ion source

plasma
and
reaction gas ions

- without additional
magnetic field:
diode-sputter-source
- with additional
magnetic field:
magnetron-sputtersource

metal ions
target material
evaporator
additional
magnet system
vacuum pump
+

WZL/Fraunhofer IPT

- 1-5 kV

Seite 53

In einem Niederdruckplasma wird ein Inertgas (z.B. Argon) durch Anlegen einer
Hochspannung ionisiert. Die positiv geladenen Inertgasionen werden auf das als Kathode
geschaltete Target (Schichtwerkstoff) hin beschleunigt und schlagen dort durch
Impulsaustausch Atome, Atomgruppen und Molekle des Beschichtungsmaterials
heraus.

53

PVD-process Arc-ion plating

-

gas inlet
inert process gas
reaction gas

105000 V
bias voltage

specimen holder
coating
plasma
and
reaction gas ions

rotating arc
plasma channel

metal ions

magnets for arc stabilizing

resp. steering
vacuum pump
WZL/Fraunhofer IPT

Seite 54

Beim Ionenplattieren wird das Substrat mit einer negativen Spannung, die sog.
Biasspannung, beaufschlagt. Der Metalldampf wird durch im Gasraum angeordnete
Elektroden und elektromagnetische Felder ionisiert. Ein Teil der ionisierten Teilchen
wird zum Substrat hin beschleunigt.

54

Example for a coating machine

WZL/Fraunhofer IPT

Seite 55

55

Coating prevents built-up edges

vC = 63 m/min broaching oil

vC = 63 m/min dry

vC = 63 m/min dry

PVD - TiN - coated

vC = 63 m/min dry

0,2 mm

workpiece material:
17CrNiMo 6 BG
tool material:
WC 6 Co
rise per tooth:
h - 0,1 mm
WZL/Fraunhofer IPT

cutting tool geometrie:

5 9 0 35m
Seite 56

Becaue of the use of PVD-TiN- coated instead of uncoated cemented carbides the builtup-edge formation is supressed in the complete examined cutting speed area of vc = 10
63 m/min because of the decreased adhesion between the chip and cutting material.

56

Physical and chemical properties of coatings

TiC
micro hardness
/ HV 0,05

TiN

Ti(C,N)

(Ti,Al)N

-Al2O3

3100

2300

2600 3400

2400 3300

2300

enthalpy of forming
H298K / kJ/mol

-184,1

-337,6

-260,0*

-156,3*

-1675,7

coefficient of
thermal exspansion
25/1000 / 10-6/K

7,7

9,4

8,0

chemical resistance

mean

good

mean

very
good

very
good

*data for the cubic NaCl-structure at 50% TiC/TiN or TiN/AlN

WZL/Fraunhofer IPT

Seite 57

57

Notch Wear and Abrasion

Dry

Synthetic Ester
Process:
Turning (external)

VBN = 0,2 mm

HC-P10
(TiAlN)
= 37 min

= 69 min

Material:
42CrMo4V
Inserts:
HW-P10, HC-P10
(SPUN 120304)

100m

Cutting parameter:
vc = 150 m/min
f = 0,12 mm
ap = 1,0 mm

HW-P10
= 48 min

Substrate
Spalling
WZL/Fraunhofer IPT

= 23 min

Abrasion

Notch
Seite 58

58

overview

tc = 40 min

tc = 57 min

VB

Nn

50

600 m
wear of minor cutting edge

100

tc = 57 min
VBNma

150

VB Nn

200

VBN max

VBN max

Width of wear land VB, NmaxVB Nn

Oxidation Resistant Coating Systems

(Ti,Hf,Cr)N

(Ti,Al)N
-Reference-

(Ti,Al)N/Al2O3

300 m

ester with additives

Process:
Ext. cyl. turning
Material:
X5CrNi18-10
WZL/Fraunhofer IPT

Cutting material:
:
HC-K20
(SPUN 120308)

Cutting parameters:
:
vc = 150 m/min
f = 0,12 mm
ap = 2,5 mm

Cooling lubricant:
:
Ester without add.

Seite 59

59

Structure
Introduction
Tool steel
Cemented carbide
Coatings

Summary

WZL/Fraunhofer IPT

Seite 60

60

Questions

Which are the main components in high speed steel (HS), WC-Co-based cemented

carbides (HW) and cermets (HT)?

Why are complex tools such as broaching and gear hobbing mills often made of high

speed steel (HS)!

Why do cermets (HT) have a higher thermal strength than WC-Co-based cemented

carbides (HW)?

A given finishing turning process does not deliver the required surface finish. The surface

obtained is too rough. What measures can be taken to increase the surface finish.

Cemented carbides from the P-group have high content of TiC, TaC and NbC carbides,

low content of WC. What is the benefit of this composition, what are the disadvantages?

What are the advantages of CVD-coatings compared to PVD-coatings?

A high speed steel has to be coated. What type of process (CVD, PCD) do you consider.

What wear effects can be influenced by a coating?

What are main failure effects of coating?
WZL/Fraunhofer IPT

Seite 61

61

Questions

How does particle size in cemented carbides influence toughness

What can be done to overcome build up edges

What are the main conditions to promote adhesive wear

What can be done to prevent adhesion

Which material more sensitive to adhesion (compare against tool steel): Aluminum,

carbon steel (0,6% C) or grey cast iron (GG 15)

Show for K - grade carbides the dependence of grit size and cobalt contend on

toughness

Show for K - grade carbides the dependence of grit size and cobalt contend on hardness

WZL/Fraunhofer IPT

Seite 62

62