Ideal edge preparation and micro-structuring

Ideal edge preparation and micro-structuring

Depending on the application an optimal rounded cutting edge exists where a coated high precision tool shows its full performance capabilities.

Edge rounding, micro-structuring and high-end coating in harmony with the application,
that is processing in perfection

s-performance 4.x is a comprehensive service package in which not only the coating process itself but also micro-structuring of geometry and surface – the basis for successful coating – make a significant contribution to your value chain.

There is now a practically endless range of coatings and coating systems, brands and technologies, combination and modular systems. Ultimately, however, it is apparent that just a few coatings could serve a major portion of all applications - provided their potential is exploited to the full. This is where the s-performance 4.x service package takes its cue, assuring the optimum combination of micro-structuring of geometry and surface, and coating, for every application, every tool type, and every tool material. Optimised harmonisation of the individual operations with one another is, ultimately, what makes the difference. Standard preparation procedures serve more to simply clean tool surfaces for coatability. Here, various coatings achieve extremely divergent results, without actually maximising the potentials of the individual coatings.

A cutting tool with a chipped cutting edge, for example, behaves in Zone I of the wear diagram only slightly differently when the coating system is changed. Only systematic micro-texturing of the surface at the cutting edge, and its application-tailored and uniform rounding-off, optimise tool behaviour during the initial cutting phase.

It is possible to achieve a significant increase in performance using one and the same coating system when the optimisation of corner- and edge-rounding, the uniformity of modification and micro-structuring or polishing of surfaces are brought more sharply into focus. Existing concepts are then raised to a new level of performance. s-performance 4.x re-evaluates and modifies/optimises existing but up to now not totally successful solutions.

When preparation was optimised for the specific application and the coated tools correspondingly post-treated, the performance advances were significant, and were virtually independent of the specific high-performance coatings tested. The processes used to apply the coatings also made no difference. Coating design and architecture do have an influence on the absolute improvement in performance, depending on the machining task. The relative differences between coatings of the same design but differing composition was marginal, assuming optimised preparation, however.

In other words, using s-performance 4.x means less the need to ask "What coating for what application?" than deciding "What combination of optimised preparation and coating achieves the best solution?".

All widely used tool materials can be performance-optimised using s‑perfomance 4.x. The tool materials themselves, and tool geometry, determine the process and machine technology to be employed for micro-structuring and preparation, the processes and the process cycle, the fluids and media to be used, and the coating processes.