In industry High Speed Machining (HSM) is recognized as one of the key manufacturing technologies for higher productivity and lower production costs. The problem in high speed machining of steel is the poor availability of good cutting tools. Existing cutting tools are coated to improve the tool life and the performance. These coatings are all based on the principle that the coating is much harder than the work piece material. However this principle is reaching the end of its possibilities, since the possibilities for further increase of the hardness are only marginal. The objective of this project is to develop new coatings for cutting tools based on a new approach: low friction MoS2 composite coatings. These new coatings will combine high hardness with low friction. These coatings will have a very low friction and will allow higher cutting speed. Dry machining will become possible in some cases: because of the low friction the use of coolant is not necessary. Also lower temperatures and a smoother cutting process will accuracy, which can Lead to higher accuracy of products. The major technical achievements include: - realisation and optimalisation of low friction MoS2 composite coating on cutting tools for high speed machining of steel. - Realisation of a MoS2composite coating at the same cost as a normal TiN coating. realisation of a pilot coating process and equipment for MoS2 composite coatings. The technical tasks include an assessment of machining performance of existing coated tools, the development of substrates and tools for the low friction coatings and the development of coatings and coating processes using a Closed Field Unbalanced Magnetron sputter Ion Plating system. In parallel worth will be carried out on a quality assurance system, including FEM analysis. Functional testing of the coatings will be performed in laboratory and at the end users on selected work piece materials. The consortium includes a SME coating company, a SME manufacturer of high speed milling machines, a SME manufacturer of lathes, a SME tool and die shop manufacturer and a tool manufacturer, supported by a university and 2 research institutes.
Funding SchemeCRS - Cooperative research contracts
5600 MB Eindhoven
7300 AM Apeldoorn
5981 NK Aa Panningen