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The Most Flexible Coating Unit of the World


S ES Y N I S IT y BU TUN ead W R -R k NE PPO tion Wee O duc a in Prowith

YOUR VERY OWN

PVD COATING

Integrated Into Your Production

Very Affordable & Competitive while providing your customers with ALL • "Standard" Coatings like AlTiN • "State of the Art" Coatings like AlCrN & • "Future" Coatings like QuadCoatings4® Additional Upgrade Options: • OXI Coatings • DLC Coatings • SCiL (sputtered) Coatings • LACS® Hybrid Coatings • Bring Coating Expertise "In-house" • Offer Rush Orders and Delivery with Coating Included • Reduced Operating Costs for Coating, Packing & Handling, Shipping • Offer a Highly Flexible Production Schedule Yielding with Low Inventory Level • Dedicated Coating Properties for Your Tools • High Reliability - High Quality Build • Environmentally-friendly Process


MoDeC® Innovations PLATIT's coating concept - Modular Dedicated Coating - allows the configuration of the number of cathodes, type, and position ® according to the coating task. MoDeC is the driving force behind PLATIT innovations. New coatings and units are developed bearing this principle in mind.

2 LARC®+ cathodes LARC® technology: LAteral Rotating Cathodes • The new generation of the first industrial coating unit for Nanocomposite coatings • The heart of turnkey coating systems for small and medium enterprises • Selected TripleCoatings3® • Coatable volume: ø355x460 mm • Loading with ø10mm end mills: 288 pieces • 5 batches / day

PL

• High volume compact unit • The "workhorse" for coating centers • 4 planar cathodes • Conventional and selected TripleCoatings3® • Usable plasma volume: ø700x750 mm • Coatable volume: ø700x700 mm • Loading with ø10mm end mills: 1056 pieces • 3 batches / day

4

MoDe

Patented in


Series PLATIT's entire product line consists of "compact" coating units. These units come in one piece, with the coating chamber in the same cabinet as the electronics. This eliminates the need of costly and time consuming on-site assembly.

High performance compact coating unit • is the basic machine ® • 3 LARC + cathodes Modular upgradeable with options: 2 • DLC option TURBO • option ® ® • 3 LARC + cathodes + 1 CERC cathode ® • high productivity with CERC booster

eC

2003

® • OXI option ® • SCiL option: high performance sputtering ® ® • 3 LARC + cathodes + 1 central SCiL cathode ® • LACS option: Simultan LAteral ARCing + CEntral sputtering • For conventional and Nanocomposite coatings • All TripleCoatings3® and Coatings4® • Coatable volume: ø500x460 mm • Loading with ø10mm end mills: 504 pieces • 5 (up to 6) batches / day

®

Combination of LARC and planar ARC technologies • High volume compact unit ® • 3 newly developed LARC -XL rotating cathodes in the door • 2 planar cathodes in the back as boosters • All 5 cathodes can deposit simultaneously • For conventional and Nanocomposite coatings • Most TripleCoatings3® Coatings4® and • Usable plasma volume: ø700 x 750 mm • Coatable volume: ø700 x 700 mm • Loading with ø10mm end mills: 1056 pieces • 3 batches / day

5


PLATIT The High Performance Machine General Information • Compact hard coating unit • Based on PLATIT LARC®, CERC® and SCiL® technologies LAteral Rotating Cathodes, CEntral Rotating Cathodes ® and Sputtered Coatings induced by LARC-GD • Coating on tool steels (TS) above 230 °C, high speed steels (HSS) 350 - 500 °C and on tungsten carbide (WC) between 350 - 550 °C • Reconfigurable by the user into different cathode setups: A: 3 LARC® cathodes and 1 CERC® cathode B: 3 LARC® cathodes ( ) ® ® C: 3 LARC cathodes and 1 SCiL cathode

Coatings • Monolayers, Multilayers, Nanogradients, Nanolayers, Nanocomposites, TripleCoatings3®, QuadCoatings4®, SCiL®-Coatings and their combinations ® ® ® • Main standard coatings: AlCrN3 , nACRo4 , ALL4 ® ® 3 4 Coatings • All TripleCoatings and ® ® • All SCiL and LACS -Coatings available

Hardware

6

• Foot print: W2720 x D1721 x H2149 mm • Vacuum chamber, internal sizes: W650 x D670 x H675 mm • Coatable volume: Ø500 x H460 mm • Max. load: 200 kg • System with turbo molecular pump • Revolutionary rotating (tubular) cathode system with 3 LARC®+ / 1 CERC® cathodes: • Magnetic Coil Confinement (MACC) for ARC control • LARC®+: Up to 200A ARC current • Changing time for skilled operator: approx. 15-30 min/cathode ® • CERC : Up to 300A ARC current ® • SCiL : Up to 30 kW sputtering power ® ® • VIRTUAL SHUTTER and TUBE SHUTTER with dedicated door shielding • Ionic plasma cleaning: • etching with gas (Ar/H2); glow discharge • metal ion etching (Ti, Cr) ® ® • LGD : LARC Glow Discharge • Pulsed BIAS supply (350 kHz) • 6 (+1) gas channels, 6 MFC controlled • Special dust filters for heaters (24 kW) • Preheater • Electrical connection: 3x400 V, 160 A, 50-60 Hz, 76 kVA 2 • Upgradeable to +OXI, +DLC , +SCiL, and to all at user's site • All options upgradeable at user's site

Electronics and Software • New HMI (Human Machine Interface) • Control system with touch-screen menu driven concept • No programming knowledge is required for control • Data logging and real-time viewing of process parameters • Remote diagnostics and control • Insite operator's manual and on CD-ROM • Enhanced operating software compatible to and

Optimal Cycle Times* • Shank tools (2 µm): ø 10 x 70 mm, 504 pcs: 4 h • Inserts (3 µm): ø 20 x 6 mm, 2940 pcs: 4.5 h • Hobs (4 µm): ø 80 x 180 mm, 28 pcs: 6 h *: The cycle times can be achieved under the following conditions: • solid carbide tools (no outgassing necessary) • high quality cleaning before the coating process (short etching) • continuous operation (pre-heated chamber) • 4-cathode processes • use of fast cooling (e.g. with helium, opening the chamber at 200°C) • 5 (up to 6) batches / day


Coating Technologies of SCiL® HYBRID® LACS

®

by

GD

LARC®+

TURBO LARC®+CERC®

TripleCoatings3®

LARC®

Coatings4®

TripleCoatings3®

ARC Technology with Rotating Cathodes

LARC

®

• LARC + LAteral Rotating Cathodes

®

DLC2® Option • PVD/PECVD process for deposition of a-C:H:X coatings

CERC® Option +

• CERC® CEntral Rotating Cathode as booster

TURBO

®

CERC

OXI Option • For deposition of oxide and oxynitride coatings

SCiL® Option • Sputtered Coatings induced by

®

GD

LACS® Option • Lateral ARC & Central Sputtering simultaneously

SCiL® LACS® 7


Coating Technologies of Simultaneous Lateral ARC and Central Sputtering ARC-Evaporation • High ionization degree • High coating density, high coating hardness • Excellent adhesion • High productivity LARC®+CERC® • Droplets cause rougher surface

®

SCiL High Performance Sputtering • Lower ionization degree • Lower coating density and hardness • Moderate adhesion • Lower deposition rate • Few droplets, smooth surface

ARC-Technology: LARC®+: LAteral Rotating Cathodes

®

Sputter-Technology: SCiL : Sputter Coatings Induced by LGD® LGD® : Lateral Glow Discharge

CERC®: CEntral Rotating Cathodes

Options of flexible coating units for cutting tools: • ARC-Technology for ~85% of the coatings for cutting tools • 4 generations of coatings • Milling, hobbing, drilling, sawing, fine blanking, etc. • PECVD-Technology for DLC2 coating 2 • Titan cutting with DLC top coating • SCiL: High performance sputtering for smooth coatings • Tapping - Aluminum cutting with TiB2 • LACS® Hybrid-Technology: LAteral ARC and Central Sputtering simultaneously

LACS®

Using Coating Material Components to Increase Performance Al: Heat resistance: Cr: Thoughness + abrasive wear resistance: Al/Cr/Ti: Nanolayer: thoughness: Ti: risk for break out: Bor: chemical stability: AlCrN3-NL (standard)

AlCrSiN (market)

AlCrN3-NL (optimized)

(AlCrN+ AlCrN/SiN)4

(AlCrN+ AlCrTiN)4

160

Si

140

NL

Ti

Bor

Flank wear [µm]

120 100 80 60 40 20 0

8

0

10

20

50 30 40 60 Tool life / tooth [m] HSS hobbing - mn = 2.31, vc = 150 m/min, fa = 1.69 mm/rev, zo = 5, dry Measured by the 1-tooth test at the University Magdeburg, IFQ, Germany


Ring Cathodes and Their Coatings Ring Cathodes* for SCiL with Ti, Al, Cr, AlCr, AlTi, Bx, Six, TiB2, ...W

1. Cathode body, incl. magnetic & electronic systems 2. Holed pipe for coolant inlet 3. Membrane pipe, tensed by inside cooling water for good conduction to the rings 4. Target rings The non alloyed cathode allows the flexible programming and deposition of the coating stoichiometry. *Patent pending

substrate

AlCrN based market coating

140

AlCrN/BN Boron: X%

AlCrN/BN Boron: Y%

120 Average wear [µm]

gradient layer

adhesion layer

Using Boron as a Material Component for Optimizing the Coatings' Internal Stress

100 80 60 40 20 0

AlCrN/BN coating with triple structure measured by energy dispersed by X-Ray spectroscopy Source: University Freiberg, Germany

Main Coatings of the Options

Coatings Machines

0

20

40

60

80 100 120 tc: Milling time [min]

140

160

Options Conventional Coatings

Nanocomposite Coatings

cVIc , CROMVIc2 , CROMTIVIc2®

TURBO

TiN, TiCN, CrN, CrTiN, nACo2®, nACRo2® ZrN, AlTiN, AlCrN

®

TripleCoatings3® ®

nACo2®, nACRo2®

DLC

®

Coatings4® ®

AlCrN3 , TiXCo3 , AlTiCrN3®

ALL4 nACRo4®

nACo3 , nACRo3 , AlCrN3®, TiXCo3®,

nACo4 , nACRo4 , TiXCo4®, AlTiCrN4®, AlCrTiN4=ALL4®+Tribo

,

®

nACVIc2® ®

®

®

OXI

LACS

200

Mat.: Tool steel - 1.2085 – X33CrS16 – HRC 29.2 – ap=5 mm – ae=02.5 mm – vc=120 m/min Tools: d=8mm - Fraisa NX-V Torus – d=2.2 mm – z=4 – fz=0.06 mm/tooth – MQL Average wear = (Max. margin wear + VBmax (clearence wear) + Top edge wear + corner wear) / 4

TiN, TiCN, CrN, CrTiN, ZrN,

SCiL

180

®

nACoX4®

TiN, TiB2

TiCC

AlTiN-LACS, AlCrN-LACS

BorAC =AlCrN/BN BorAT®=AlTiN/BN

®

9


®

SCiL Coatings and Their Applications Comparison of Surface Roughness: Coating Thickness for Both Cases: 2 µm Alpha = 45°

Beta = 30°

Alpha = 45° Beta = 30°

2.99 µm

0.366 µm

86.3 µm

86.1 µm

86.3 µm

86.1 µm SCiL® surface Sa= 0.0162 µm – Sz=0.311 µm

ARC surface Sa= 0.1627 µm – Sz=2.087 µm

Sputtering power: Up to 30kW No columnar structure Reactive and non-reactive processes Growth rate in reactive process: ≈ 2 µm/h in 3-fold rotation Application fields: gun drilling, tapping, decorative coatings

Torque and Force Comparison Mc; Torque [%]

Thread Forming

250 200 150 100 50 0

Torque TiCN-ebeam TiCC-SCiL 0

1

2 3 4 ap; Thread depth [mm]

5

Tools: M3 - vc=10mm/min - MQS Material: stainless steel; SUS 304 - X2CrNi19-11 The built up edge by SCiL is smaller than by eBeam

2.59

1.16

0.41

Milling

1.02

Feed force

Ff; Feed force [%]

Top layer Core Layer Adhesion layer TiCC TiCN Ti - TiN Total thickness [µm] 1. Thickness [µm] 2. Thickness [µm] 3. Thickness [µm]

200 150 100 50 0 -50 -100

TiCN-ebeam TiCC-SCiL ap; Thread depth [mm]

ComparisonCosts of thewith builtSolid up edges at aluminum cutting Production Carbide Drills Zr

O

Al

29

108

Ti

O

Al

31

102

87

27

12

W

59

C

O

Al

W

87

10

W

47

18

211 X EDX- detection frequency of the respective element: DLC3® deposited by p

10

Segmented TiB2-cathode for SCiL®-Technology

SEM and EDX after 283 m tool life Material: 3.4365 AlZnMgCu1,5 - Tool: Torus end mill Ø12mm – r=2.5mm – z=2 vc=377 m/min – ae=5mm – ap=6mm – fz=0.2 mm/rev


®

LACS Coatings and Their Applications BorAC® - Hobbing with Boron Doped AlCrN-ML 80 60 40 Al, Cr-based 20

d se

20 24.9 10

19.2

17.0

ALL4

LACS-AlCrN/BN 4

0

8

-A lC rN /B N

r-b a

Boron effect

+30%

+13%

0 12 16 hobbed gears

20

0 Reference Al, Cr-based

24

BorAC® LACS® AlCrN/BN - ML

ALL4

Fly-Hobbing test using PM-HSS - All teeth rounded by wet blasting, R = 15 - 18 µm Coating thickness for all three variations by calo test, d = 4 µm LACS-AlCrN/BN protects crater wear best vc=180 m/min - fa=3.6 mm/rev, max. chip thickness = 0.20 mm

LA CS

AL L4

Al ,C

30 tool life [m/tooth]

width of flank wear [µm]

100

BorAC® - AlCrN/BN: Cutting Performance at Milling 2.50

Cutting Performance at Milling [min/µm] 2.34

2.16

2.07

2.07

2.00

1.89 1.47

1.50 1.00 0.50 Cutting Performance Measured and Calculated as Cutting Time [min] / Average Wear [µm]

0

BorAC®

nACRo4®

AlCrN3®

AlCr-ML

AlTiN3®

AlCrN market coating Mat.: Tool steel – 1.2085 – X33CrS16 – HRC 29.2 – ap=5 mm – ae=02.5 mm – vc=120 m/min Tools: d=8 mm – Fraisa NX-V Torus – d=2.2 mm – z=4 – fz=0.06 mm/tooth – MQL Average wear = (Max. margin wear + VBmax (clearence wear) + Top edge wear + corner wear) / 4 (

)

BorAT® - AlTiN/BN: Wear Behavior at Drilling 0.50 0.45

AlTiSiN-2 market coating

0.40

TiXCo4

AlTiSiN-1

VBmax [mm]

0.35 0.30

TiXCo3

0.25

nACo4-1

0.20

nACo4-2

0.15

AlTiSiN-1 market coating

0.10 0.05

0

®

BorAT

Drill’s Corner Wear after 2178 Holes

BorAT® 0.0

5.0

45.0 25.0 35.0 20.0 30.0 40.0 Tool life [m] Mat.: Heat treated steel – 1.7225 – 42CrMo4 – HRC 30 – ap=18 mm – vc=120 m/min Tools: Solid carbide drill – d=6.8 mm – Schlenker GmbH – z=2 – f=0.15 mm/rev – MQL Measured at GFE, Schmalkalden, Germany 11

10.0

15.0


TripleCoatings3® & with

Coatings4®

TiXCo3®

nACRo3®

SCiL ®

nACo3® BorAT®: AlTiN/BN

DLC-V ® Ic

o nAC

AlCrN3®

Ro C A n

®

BorAC : AlCrN/BN

AlTiN3® CrTiN3® 12

CROMVIc2®

TiXCo 3 ®


ALL4®: ® AlCrTiN4

AlTiCrN4®

4

iN T r C l 4® : A ALL rN C i T Al AlCrN Dedic ated nACo 4 ® X

TiXCo4®

nACRo4®

nACo4® nACoX4® 13


Cathode Configurations

® 3 TripleCoatings

CrTiN3®: For Forming CrTiN - Cr/TiN-NL - CrN or TiN Cathode-positions: 1: Ti – 2: Al

– 3: Cr

– 4: none

– 3: Cr

– 4: none

AlTiN3®: For Universal Use TiN - AlTiN-G - AlTiN-NL Cathode-positions: 1: Ti – 2: Al 3®

AlCrN : For Dry Cutting Abrasive Materials CrN - Al/CrN-NL - AlCrN Cathode-positions: 1: Ti – 2: Al 3®

– 3: Cr

– 4: none

AlCrN +: AlCrN doped by Titan: TiN - AlTiN - Al/CrN-NL Cathode-positions: 1: Ti – 2: Al – 3: Cr – 4: AlTi33

AlTiCrN3®: For Dry and Wet Cutting Ti(Cr)N - Al/CrN NL - AlTiCrN Cathode-positions: 1: Ti – 2: Al

– 3: Cr

– 4: none

nACo3®: For Universal Use, Turning, Drilling TiN - AlTiN - nACo Cathode-positions: 1: Ti – 2: AlSi18 – 3: none – 4: AlTi33

nACRo3®: For Superalloys, Milling, Hobbing CrN - AlTiCrN-ML - nACRo Cathode-positions: 1: Ti – 2: AlSi18 – 3: Cr

– 4: AlTi33

TiXCo3®: For Superhard Machining, Milling, Drilling TiN - nACo - TiSiN Cathode-positions: 1: Ti – 2: Al

14

– 3: TiSi20 – 4: AlTi33

TripleCoatings3®


Coatings4® ALL4®: AlCrTiN4®: For Wet and Dry Machining CrTiN - AlCrTiN-G - Al/CrN Multilayer - AlCrTiN - (CrCN optional) Cathode-positions: 1: Ti – 2: Al – 3: Cr – 4: AlCr30

ALL4®

: Dedicated for Big Hobs

CrTiN - AlCrTiN-G - Al/CrN Multilayer - AlCrTiN - (CrCN optional) Cathode-positions: 1: CrTi15 – 2: Al – 3: Cr – 4: none

AlTiCrN4®: For Tapping and Forming CrTiN - AlTiCrN-G - Al/CrN Multilayer - AlTiCrN - (CrCN optional) Cathode-positions: 1: Ti – 2: Al – 3: Cr – 4: AlCr30

nACo4®: For Universal Use, Turning, Drilling TiN - AlTiN-G - AlTiN-NL - nACo Cathode-positions: 1: Ti – 2: Al

– 3: AlSi18 – 4: AlTi33

nACRo4®: For Superalloys, Milling, Hobbing CrN - AlCrN-G - AlCrN-NL - nACRo Cathode-positions: 1: Cr – 2: AlSi18 – 3: Cr

– 4: AlCr30

TiXCo4®: For Superhard Machining TiN - nACo-G - nATCRo-ML - TiSiN Cathode-positions: 1: Ti – 2: Al

– 3: TiSi20 – 4: AlCr30

nACoX4®: For HSC Dry Turning and Milling TiN - AlTiN - nACo - AlCrON Cathode-positions: 1: Ti – 2: AlSi18 – 3: AlCr45 – 4: AlTi33

15


Applications with Classic Operations Sawing

Tool Life Comparison 14000

tool life [work pieces] 12000

12000 10000 8000

6700

6000 3200

4000 2000 0

Tapping

nACVIc® nACRo®+CBC (DLC1) Precision cutting of 3 mm profiles, stainless steel 904L Tool: carbide circular saw blade Ø 160mm x 0,8mm, z=200 Cutting conditions: n=400 rev/min, vf=64 mm/min, lubrication: oil Life time criterion: Burr formation on work piece Source: Swiss Watch Industry

AlCrN

AlTiN/TiSiN

Comparison Costs of Cutting TiCNDrills and CROMTIVIc2 (DLC2) Production withTorque Solid with Carbide 40 30

TiCN coated

CROMTIVIc2 tool 1

CROMTIVIc2 tool 2

Torque Md / Nm

20 10

Cutting torque

0

Back driving torque

-10 -20 -30 -40 0

10

20

30 40 50 60 Number of true-to-gauge threads

70

80

90

Material: TiAl6V4 - Tap: HSS - M10 - Thread depth ap=24 mm vc = 8 m/min - Core hole diameter: dc=8.5 mm - Coolant: Emulsion 10 % - external - p=50 bar Source: IGF project - RWTH Aachen, Germany

Injection Molding

Aluminum Injection Mold with Dedicated Multilayer-nACRo 200

tool life [%]

150

150

100

100

50

0

16

AlCrN nACRo Source: Gibbs Die Casting Ltd. Retsag, Hungary


Hobbing, Fine Blanking, Drilling with TripleCoatings3® Productivity Improvement with Higher Speed and Feed

Drilling

180% 160%

TiAlN

140% 120% 100%

nACo3

2304

200 0.43 140

34050 35025

0.39

1475

4717

2.44

80%

3146

1.56

60% 40% 20% 0%

vc [m/min]

f [mm/rev]

Lm [holes]

productivity vf [mm/min]

tc/hole [sec] machine+tools costs/tool use [€]

Work piece material: GGG40 – ap=60 mm Solid carbide step drill: d=7.1/12 mm – Internal cooling with 70 bar - 5 % emulsion Source: Sauer Danfoss, Steerings, Denmark

Hobbing 160

0

4

2

tool life: Lmz [m/tooth] 8 10 12

6

14

18

16

20

VBmax [µm]

VBmax=130µm 120

AlTiN

AlCrN Nanosphere

80 40 0

0

5

10

15 20 No. of produced gears

25

30

Mat.: 20MnCrB5 - Tool: PM-HSS - m=2.7 - Down hill milling - vc=220 m/min - fa=3.6 mm – dry Source: IFQ Magdeburg in the development project LMT-Fette - PLATIT The patented Nanosphere coating is a result of a common development project, exclusively for LMT-Fette

Fine Blanking

Comparative Analysis (SEM) after 30'000 Strokes

TiCN Coating detached, maintenance urgently needed.

Standard-AlCrN Element requires preventive maintenance.

Dedicated TripleCoating3® based on AlCrN3® Element can continue in service.

Source: Feintool, Lyss, Switzerland

17


Applications with Hard Cutting Wear Comparison

VB [µm]

Super Hard Milling 180 160 140 120 100 80 60 40 20 0

183

102

VBave

97

VBmax

86

72

67

60

44

AlTiN (market coating)

nACRo3®

AlTiN + AlCrN (market coating)

TiXCo3®

Torus end mill in cold-working steel X210Cr12 (1.2080) - 61.5 HRC - ø8 mm - z=4 - ap=0.1mm - ae=3mm - vc=100m/min n=4000 1/min - fz=0.2mm - vf=3200mm/min - dry - Source: Development project LMT Fette-PLATIT

Hard Milling

Wear Comparison in Hot Working Steel, 54HRC 160

Wear after 27 m milling [µm] VB [µm]

142

140

124

120

100

100 80 60

55

55

70

60 38

35

40

20

20 0

Drilling

Corner wear [µm]

AlTiN2 AlCrN2 TiXCo4 AlCrN/TiSiN3 market coating market coating market coating Tool: Solid carbide endmill - d=8mm - vc=100m/min - ap=4mm - ae=0.03mm Coolant: Emulsion - Coating thickness: 2 µm - Edge radius: 7 µm - Cutting length: 27m Work piece material: Hot working steel - 1.2344 / SKD61 - 54 HRC Source: Tool manufacturer, China

TiCN2 market coating

Tool Life Comparison in High Strength Steel 80

Tool Life [m]

70.2

70 60 50 40

45.3

47.6

31.7

30 20 10 0

18

nACo3 AlCrN1 TiXCo4 TiAlSiN2 market coating market coating Work piece material: X155CrVMo12 - 1.2379 - Rm=1150 N/mm2 - Coolant emulsion 7% Tool: solid carbide drill: ø6.8 mm - Edge preparation: 50 µm - Coating thickness: 3 µm vc=70 m/min - f=0.16mm/rev - ap=15 mm - Tested at GFE, Schmalkalden, Germany


Coatings4®

Turning, Hobbing, Fine Blanking with OXI-Option: Oxide Quad-Coatings versus CVD at Turning of High Alloyed Steel nACoX4® PVD 3 µm

CVD

nACoX4® PVD 6 µm

800 700

nACoX4® PVD 9.5 µm

+ 77% Cutting Time

Wear VB [µm]

600 500 400 300 200 100 0

SME can more than compete with CVD using their own, thick PVD-OXI-coatings!

75 175 0 50 100 150 200 25 125 225 250 ~35 cycles ~62 cycles Cutting time [sec] Inserts: WNMG – vc=110 m/min – f=0.4mm – Cutting length/cycle: 6.42m Material Ni-steel – Rm=620 N/mm2 – Coolant: MQS Source: Daimler AG, Stuttgart, Germany

Flank wear on AlCrSi-based market coating with thickness of 3.9 µm after tool life end Lf = 24 m

Flank wear on nACRo4® with thickness of 4.0 µm after tool life end Lf = 32 m

tool life [m/tooth]

Tool Life Comparison at Dry Hobbing

Hobbing

500 µm

50 45 40 35 30 25 20 15 10 5 0

48.2

32 24

22

14

AlCrSi based market coating thin (3.3 µm)

AlCrSi based market coating thick (3.9 µm)

AlTiCrN3

nACRo4 thick (4 µm)

ALL4: AlCrTiN4

Mat. : 20 MnCrB5 - m=2.7 Tool: 2-teeth - PM-HSS - vc=150 m/min - fa=1.7/work piece revolution - with 5 gears Measured at the University of Magdeburg, Germany

Applications with ALL4® + Tribo

Fine Blanking

Work piece material: stainless steel 1.4509 (X2CrTiNb18) Tool life [# work pieces] 20000 17000 15000 8000

10000 5000 0

500 TiCN

AlCrN3

ALL4+Tribo

Source: Feintool Technologie AG

Work piece material: stainless steel 1.4301 2mm thick Tool life [# work pieces] 30000 25000 25000 20000 14000 15000 10000 5000 1000 0 ALL4+Tribo TiCN AlCrN3 Source: Feintool, Lyss, Switzerland

19


Lightweight Carousels for Max. usable diameters Dx / Dy mm

Single rotation carousel D1=550 for saw blades D2=460 mm for molds and dies

3 (6) axis carousel D3=220 / D6=150

3 axis carousel for saw blades with overlap Max. saw blade D=285 mm

max Ø215

Ø115 max

7 axis carousel D7=143

Ø183 max

20

4 (8) axis carousel D4=215 / D8=115

5 (10) axis carousel D5=175 / D10= 94

12 (6) axis carousel D12=100 / D6=145

14 axis carousel D14= 85

max Ø250

4 axis dedicated asymmetric carousel D3=183 / D1=250


Holders for Cutting Tools Holders Gearboxes for triple rotation for shank tools with shank diameter D and with gear positions #N

Quad-Gearboxes (4-fold rotation)

Application D<=52 mm (2") - N= 4 - for big shank tools, special sleeves Outer D=143 mm - Outer D=173 mm D<=40mm - N=6 D<=25mm - N=8 - N=10 D<=20mm - N=12 D<=14mm - N=18 - N=22 The tools are rotating uninterruptedly around the own axes. It allows very homogeneous coating around the tools. Gearboxes make loading of batches significantly easier. No need for sensitive setting of kickers. For holding big quantities of shank tools D= 1 mm - 3/8": 5 x 14 positions = 70 tools D= 4 mm - 8 mm: 5 x 9 positions = 45 tools The whole batch usually contains the same tools. They are rotating around their own axes.

Sleeves

For standard shank tools. Diameters: [mm] 6, 8, 10, 12, 14, 16, 18, 20, 22, 25, 32 and 1/8", 3/16", 1/4", 3/8", 1/2",4/7", 5/8", 3/4", 7/8", 1"

Insert holders with satellites and rods

Special diameters on request Satellites for inserts with diameter / edge length [mm] d / â&#x2DC;? : 8.5, 12, 14, 19, 20, 27, 29.5, 42

Hob holders for shank hobs and bore hobs

Satellites positions: 6, 9, 15, 18 Support ring for rods of small inserts. Rods according to the hole diameters of the inserts: d > 2.4, 3.7, 4.2, 5.2, 6.2 mm TongS keep the inserts without holes, spindled on special rods. TongS are products of 4pvd, Aachen, Germany. The parts of hob satellites are set together according to the sizes and dimensions of the different hobs.

Vertical holders for fine blanking tools, punches and components

Flat parts, punches, and fine blanking tools should be coated on one side only. Therefore only double rotation is necessary. The vertical holders with slots enable flexible clamping of the tools by screws or magnets.

21


Turnkey Solutions

PL Quality Control Handling

22

Cleaning


The integration of flexible coating into the manufacturing production requires complete turnkey solutions. PLATIT offers complete coating systems including all necessary peripheral equipment and technologies for: •surface pretreatment by polishing, brushing and/or micro blasting, •one-chamber vacuum cleaning with "start-and-forget" operation, •stripping of coatings from HSS and carbides, •handling for loading and unloading of substrates and cathodes, •and quality control systems according to ISO 9001.

Coating

Pre- and PostTreatment Stripping

23


Coating Guide Coating Usage Recommendations Cutting Turning

Steels unalloyed < 1000 N/mm2

Chipless Forming

Milling - Hobbing Drilling Reaming Gear Cutting Broaching Sawing

Tapping

Injection molding

Stamping Punching

Forming Deep Drawing Extrusion

nACo

ALL4®

nACo

AlTiCrN

nACVIc

AlCrN

AlTiCrN (+CrCN)

AlTiN

nACRo

AlTiN

TiCC

CrTiN

nACVIc

TiCC

Steels unalloyed > 1000 N/mm2

nACo

ALL4®

nACo

AlTiCrN

nACVIc

AlCrN

AlTiCrN (+CrCN)

AlTiN

nACRo

AlTiN

TiCC

CrN

ALL4®

TiCC

Steels hardened < 55 HRC

nACo

nACo

nACo

nACo

AlCrN

TiXCo

TiXCo

TiXCo

TiCC

ALL4®

Steels hardened > 55 HRC

TiXCo

TiXCo

TiXCo

TiXCo

AlCrN

nACo

nACo

nACo

nACo

nACo

ALL4®

nACo

ALL4®

ALL4®(+CrCN)

ALL4®(+CrCN)

ALL4®(+CrCN)

Stainless steel

nACRo

TiXCo

TiCC

CROMTIVIc

CROMTIVIc

CROMTIVIc

nACoX4®

nACoX4®

TiXCo

nACVIc

nACVIc

nACVIc

nACVIc

nACo

AlTiCrN

nACo

TiCC

CROMTIVIc

CROMTIVIc

CROMTIVIc

ALL4®

nACRo

nACRo

CROMTIVIc

nACVIc

nACVIc

nACVIc

nACRo

ALL4®

ALL4®

TiCC

CROMTIVIc

CROMTIVIc

CROMTIVIc

nACo

nACo

nACo

nACRo

AlTiN

AlTiN

AlTiN

AlTiCrN

nACRo

nACRo

nACRo

nACRo

nACRo

AlCrN

nACVIc

TiCN

TiCN

TiCN

TiCC

TiCN

TiB2

TiB2

TiB2

TiB2

TiB2

TiB2

TiB2

ZrN

ZrN

ZrN

ZrN

ZrN

ZrN

ZrN

CROMVIc3®

CROMVIc3®

CROMVIc3®

CROMVIc3®

CROMVIc3®

CROMVIc3®

CROMVIc3®

CrN

CrN

CrN

CrN

CrN

CrN

CrN

TiCN

TiCN

TiCN

TiCC

TiCN

TiCN

TiCN

CROMTIVIc

CROMTIVIc

CROMTIVIc

CROMTIVIc

CROMTIVIc

CROMTIVIc

CROMTIVIc

CROMVIc3®

CROMVIc3®

CROMVIc3®

CROMVIc3®

TiXCo3®

TiXCo3®

TiXCo3®

TiXCo3®

nACoX Superalloys Ni-based Superalloys Ti-based Cast iron Aluminum Si > 12% Aluminum Si < 12% Copper Bronze, Brass, Plastic Graphite Carbon-fibre composites Wood

TiXCo

CROMVIc

CROMVIc

CROMVIc

CROMVIc3®

TiXCo

TiXCo

TiXCo

TiXCo

CROMTIVIc

CROMTiVic

CROMTiVic

CROMTiVic

nACVIc

nACVIc

nACVIc

nACVIc

Primary Recommendation: If available, use this coating for the application.

coating A coating B

CROMTIVIc

Alternate Recommendation: Use this coating when the primary recommendation is not available.

Editor: Dr. Tibor Cselle Pi411-2017-ev5

Design:

• Thickness and structure can and should be different according to the different application processes even for the same coating. • The exponent x (coatingx) is defined by the machine, which coating generation the machine can deposit.

Pi411plus ev5  
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