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Grade Upgrade

Grade Upgrade

Has the development of new tool materials already reached its peak and is experiencing stagnation? Find out more from Andrei Petrilin and Marcel Elkouby, ISCAR.

Grade Upgrade

Fig 1: CBN grade IB20H insert for hard part turning.‎

Building a house begins with laying the foundation. The strength and the reliability of the whole house depends on how strong the foundation is. In cutting tool engineering, this foundation is a cutting material.

There are various types of cutting materials: cemented carbide, polycrystalline diamond, high speed steel, and ceramics, to name a few. Each type contains different grades. At various stages in metal cutting history, the introduction of each cutting material and its use has led to a significant change in the level of cutting speeds and, consequently, productivity. However, if the previous century, especially its second half, was marked by the rapid progress of tool materials, today we do not see any significant new solutions in this field. Does this mean that the development of new tool materials has already reached its peak and is experiencing stagnation?

Of course not. It is simply that the new developments are deep within the cutting material and are focused on its structure, and can be observed only with the help of scanning electron microscopy (SEM), X-ray diffraction (XRD), electron backscatter diffraction (EBCD), and other sophisticated methods. They cover a tremendously complicated world of coatings that is extremely diverse despite its very small thickness, measured only by microns. 

Cemented Carbide

Grade Upgrade

Fig 2: Parting tool carrying IC1010 grade insert‎.

The most commonly available cutting material today is cemented carbide (primarily coated), also known as ‘hard metal’, ‘tungsten carbide’ or simply, carbide. In terms of performance, it represents a reasonable balance between efficiency, tool life and cost. A combination of cemented carbide, coating, and post-coating treatment produces a carbide grade. Only one of these components—the cemented carbide—is an essential element in the grade. The others are optional.

Cemented carbide is a composite material comprising hard carbide particles that are cemented together by binding metal (mainly cobalt). Most cemented carbides used for producing cutting tools integrate wear-resistant coatings. There are also various treatment processes that are applied to already coated cemented carbide (for example, the rake surface of an indexable insert). New developments in cemented carbide, as a tool material, are concentrated in three directions: carbide production technologies, advanced coating methods, and innovative post-coating techniques. Considerable success has been achieved in each of these directions; this is reflected in the wealth of new products introduced to the market by leading cutting tool manufacturers.

Cutting tool customers might analyze the grades using parameters such as productivity, tool life, and performance. Indeed, the question of how a new product was created to meet customer requirements fades into the background as applicability and efficiency form the main measure of progress from the customer’s  point of view. 

Upgrading Carbide Grades

In upgrading carbide grades, ISCAR is very sensitive to a challenge faced by the metalworking industries. In this context, ISCAR’s tool material solutions—developed considering the trends of modern metalworking—can be quite indicative. Take, for example, difficult-to-cut materials such as titanium and heat-resistant steels and exotic superalloys. Recently, the share of their application in industry has increased significantly. Along with the aircraft industry, a traditional consumer of these materials, they may be increasingly found in power engineering, automotive, and oil and gas branches. The growing usage of the materials demands technological solutions, including machinery and cutting tools. The new tools require an appropriate foundation, made of advanced cutting tool materials,  to achieve the desired cutting geometry. And for the construction of this foundation, ISCAR offers its new effective ‘bricks’—upgraded carbide grades. 


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Walter AG Releases New X.treme Evo Solid Carbide Drill With Threefold Universal Use

Walter AG Releases New X.treme Evo Solid Carbide Drill With Threefold Universal Use

With the X·treme Evo solid carbide drill from the Advance product range, Walter AG is launching the new DC160 product type.

Walter AG is releasing an all-rounder for every material, machine and drilling application. This can be used universally in three different ways: In all ISO material groups. It is designed for a wide variety of applications such as inclined entries and exits, drilling holes close to the edge of the workpiece or convex and concave surfaces. Furthermore, it can also be used with all machine concepts: In machining centres, horizontal or vertical, in lathes, rotating with driven tools, axial and radial (with angular head), or stationary. As a first step, Walter is bringing out the X·treme Evo in the variants three and five × Dc without internal coolant and five, eight and 12 × Dc with internal coolant. In addition to the DC160 variant, the drill from the Advance range is also available as the DC260 Advance step drill with and without internal coolant. According to Walter, the greatest strengths of the X·treme Evo lie in its long tool life and high levels of productivity and process reliability.

The WJ30ET (full coating) and WJ30EU (point coating) grades are new to the X·treme Evo: A highly tough micrograin substrate combined with Walter’s own TiSiAlCrN/AlTiN multi-layer coating on an AlTiN base layer. Extremely wear-resistant for a long tool life – even while maintaining high cutting parameters. Another innovation is the thinner web with steep approach angle, along with the fourth land that lies close to the drill tip. The steep approach angle reduces the feed force and increases the positioning accuracy. The deep-seated fourth land is engaged even quicker and consequently optimises drill guidance, particularly for inclined entries and exits. The new type of face geometry on the X·treme Evo creates plenty of room for the chip in the centre and therefore improves chip removal, particularly in soft material.


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Walter: Carbide Drilling Tools

Walter: Carbide Drilling Tools

Walter has developed the DC170 and is offering the first two models in dimensions 16xDc and 20xDc. The drill offers more process reliability, stability, running smoothness and efficiency than carbide drills with traditional geometries.

The drills are internally cooled. As a result, the coolant flows unimpeded, while hazardous chip jams are at the same time avoided. The manufacturer also says that the solid carbide mass directly behind the cutting edge makes the drill sturdy.

Finally, drills straight from the factory are supplied with eight visible channels that can be used as a scale for regrinding. The drills can be reconditioned up to three times, until only two cooling channels are left remaining.

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