We have exclusive tie ups & best economical prices with Major Component PVD coating companies, We always advice our clients to get the tools coated to enhance the life of cutters and also extend the feasibility of further grindings. 2 to 4 microns of PVD Coating helps the tools to strengthen its cutting ability, With feed and speed to cut, coating helps for smooth cutting and also gives extended life before the sharpness diminishes.
There are different types of coatings on gear cutters to dramatically extend the life of your tool. Offering the latest in high performance PVD coatings for most industrial applications including: Titanium Nitride (TiN), Titanium Carbonitride (TiCN), Titanium Aluminum Nitride (TiALN) or ALCRONA Pro any other coating as per client requirement.
It increases the tools life to more than 2 to 3 times, reduce the tool inventory, reduce machine downtime and increase shop efficiency.
1. Titanium Nitride (TiN) Coating is bright gold in colour with a surface hardness of 81 Rc and a 0.4 coefficient of friction. TiN has very good corrosion resistance, heat transmission and excellent wear resistance with a wide range of materials, including iron-based materials, hardened steels, and stainless steels. Forming operations can expect a decrease in galling and welding of a work piece material with a corresponding improvement in surface finish of the formed part. Increased tool life can run 3 to 8 times greater with increased feeds and speeds (finished parts per hour). Loner tool life and greater feeds and speeds depend upon the application, coolant, and other conditions. Hardness: 2800 HV; Coating Thickness: 2-4 microns; Thermal Stability: 550°s Celsius or 1000°s Fahrenheit.
2. Titanium Carbonitride (TiCN) Coating is medium gray or bronze in colour with a hardness reaching 90 Rc and a 0.3 coefficient of friction. TiCN Coating has up to 750°s Fahrenheit thermal stability. TiCN offers improved wear resistance to abrasive, adhesive, or difficult-to-machine materials such as cast iron, aluminum alloys, tool steels, copper, inconel, and titanium alloys. As in TiN, feeds and speeds can be increased and tool life can improve by as much as 800 percent depending on the application, coolant and other conditions. Hardness: 3000 HV; Coating Thickness: 2-4 microns. Thermal Stability: 400°s Celsius or 750°s Fahrenheit.
3. Titanium Aluminum Nitride (TiAIN) Coating is dark purple/black in colour with a surface hardness in the upper 80 Rc range with a coefficient of friction, which is less than Titanium Nitride (TiN). TiAIN Coating is a high performance coating, which excels at machining abrasive and difficult-to-machine materials such as cast iron, aluminum alloys, tool steels, and nickel alloys. TiAIN's improved ductility makes it an excellent choice for interrupted cutting operations. Its superior oxidation resistance provides unparalleled performance in high temperature machining. TiAIN does not exhibit edge brittleness and can be used for interrupted cuts without chipping. TiAIN Coating should be targeted at applications that generate the highest heat level at the tools cutting edge. Hardness: 2800 HV; Coating Thickness: 2-4 microns; Thermal Stability: 750°s Celsius or 1350°s Fahrenheit..
These coatings and treatments when applied to the appropriate brite tool for a given application will accomplish some or all of the following:
- increase tool life;
- reduce down-time;
- allow increased feed and speed rates, and;
- reduce tooling costs per job/piece.
- an incorrect tool choice;
- an incorrect coating choice;
- the parts material;
- the machine tools rigidity;
- the choice of feeds and speeds;
- the spindle and/or tool holder(s) run out, and;
- the type and feed of coolant, if any.
Coated and Treated cutting tools offer substantial cost reductions.
The above noted coating benefits may be diminished due to:
Alloying elements present in HSS properties:
|TREATMENT||ALSO KNOWN AS||DESCRIPTION / CHARACTERISTICS||PERFORMANCE||APPLICATIONS||PRECAUTIONS|
|ALUMINUM TITANIUM NITRIDE (AlTiN)||A black multi-layered coating of Aluminum Titanium Nitride is produced by the physical vapor deposition (PVD) process. The coating is about .0001” thickenss and is exceptionally hard (approximately 4400 Vickers hardness). AITiN has a very low coefficient of friction to reduce chip welding and tools can be operated at 25-40% faster feeds and speeds than TiN.||AITiN coated tools last up to 1000% longer than TiN coated solid carbide tools when machining hard abrasive materials and high temperature alloys. Can be used for ferrous and non-ferrous metals.||AITiN was designed specifically for use on solid carbide cutting tools to machine hard abrasive materials and hardened steels. It is used for high speed (semi-dry & dry) machining and where higher temperatures are generated.||AITiN coated tools oxidize at about 1650°F.|
|TITANIUM ALUMINUM NITRIDE (TiAlN)||A purple multi-layered coating of Titanium Aluminum Nitride is produced by the physical vapor deposition (PVD) process. The coating is about .0001” thickness and is very hard (approximately 2800 Vickers hardness). TiAIN has a very high oxidation resistance (up to 1500°F) and can be operated at 20-35% faster speeds and feeds than TiN.||TiAIN coated tools last up to 1000% longer than TiN when machining abrasive materials such as cast iron. It was designed for very high speed performance.||Used for Titanium and Nickel alloys, stainless steels, hard abrasive materials, and whenever excessive heat is generated on the cutting edge.||TiAIN coated tools may have a tendancy to gall in aluminum or brass. TiAIN coated tools oxidize at about 1500°F.|
|TITANIUM CARBONITRIDE (TiCN)||A gray multi-layered coating of Titanium Carbonitride is produced by the physical vapor deposition (PVD) process. The coating is about .0001" thickness and is exceptionally hard (approximately 4000 Vickers hardness). TiCN has a very low coefficient of friction to reduce chip welding and tools can be operated at 15- 25% faster feeds and speeds than TiN.||TiCN coated tools last up to 300% longer than TiN when machining tool steels and abrasive materials. The performance of TiCN coated HSS tools is comparable to solid carbide tools.||Used for alloy steels, tool steels, and abrasive materials like cast iron and high silicon aluminum alloys.||TiCN coated tools may have a tendency to gall in Ni or Ti alloys. TiCN coated tools oxidize at about 750°F.|
|TITANIUM NITRIDE (TiN)||Usually any trade name ending with -Tanium suffix||A bright gold coating of Titanium Nitride is produced by the physical vapor deposition (PVD) process. The coating is about .0001" thickness and is approximately Rc80 hardness. It refracts heat and acts as a thermal barrier between the chip and the tool. TiN has a very low coefficient of friction to reduce chip welding and tools can be operated at high speeds and feeds.||TiN coated tools last from 200 to 700% longer than uncoated tools. Performance will vary by material and cutting tool. The harder the base material of the tool, the more effective TiN coating will be||Used for ferrous metals below Rc40 hardness and for non-ferrous metals where increased metal removal rates signify productivity.||TiN coated tools have a tendency to gall in Titanium and Titanium alloys. TiN coated tools oxide at approximately 900° F.|