Die casting is a type of metal casting in which dies are used t

• Posted by Dani Bogdan September 8, 2022 - Filed in Technology - #die casting manufacturer  - 546 views

  It is unavoidable that the tools used in the CNC processing process will become worn over time when working with aluminum alloy die casting and mold blanks. Tool discarding is only possible when the tool has become excessively worn. By doing so, the tool's service life can be extended while the cost of aluminum alloy die casting can be reduced in a covert fashion as well. To increase the service life of the cutting tools while also improving machining efficiency, the coating technology will be implemented for the current cutting tools. In this article, we will discuss the factors that contribute to tool wear in aluminum die casting operations, as well as strategies for reducing tool wear in these processes.
  
  Tool Wear is available in a variety of designs.
  
  It is common to encounter the following types of tool wear while working on construction sites:
  
  1 Deterioration of the scoring surfaces on the flanks of the body2 Wear on the body's flanks3 The crater is showing signs of wear and tear.
  
  On number four, the cutting edge is sharp with a rounded tip.
  
  The following are five examples of cutting-edge collapses that have occurred recently.
  
  6 Stay on the cutting edge of technological advancements.
  
  The occurrence of catastrophic failures has occurred seven times so far.
  
  The following are the factors that contribute to tool wear:
  
  In the metal cutting process for aluminum alloy die castings or mold blanks, the manifestations of energy include heated air and friction, which occur during the die casting or mold blanks' metal cutting process. It becomes extremely difficult to machine when the tool is subjected to a high surface load, as well as when there is a lot of heat and friction generated by chips sliding quickly along the tool rake face. Sometimes the cutting force will change direction and fluctuate in both directions, which is primarily determined by the differences in operating conditions. High hardness, excellent toughness, and wear resistance are just a few of the fundamental characteristics that a tool must possess in order to maintain its strength even when subjected to high cutting temperatures, amongst other characteristics.
  
  How to reduce tool wear and extend the life of your tools is covered in this article.
  
  A widely accepted unified definition of tool life in the literature does not exist at this time; however, workpiece and tool materials, as well as the cutting process used, are all factors that influence tool life. In order to begin a quantitative analysis of the end point of tool life, one approach is to establish an acceptable maximum flank wear limit as a starting point before proceeding with the quantitative analysis of the end point of tool life.
  
  Developing optimal tool substrate, coating, and cutting edge preparation technology on a continuous basis is required for high-speed cutting to be successful. This is especially important for limiting tool wear and resisting high-temperature cutting. These considerations, in addition to the chip breaking groove and corner arc radius that have been adopted on the indexable blade, are used to determine the suitability of each tool for different workpieces and machining tasks. Through the use of the most effective combination of all of these elements, it is possible to reduce tool wear and tool life while simultaneously making the cutting process more cost-effective and dependable while simultaneously increasing productivity.
  
  When selecting coated tools, make sure that they are of the highest quality.
  
  The coating also contributes to the enhancement of the tool's cutting performance. Some examples of current coating technologies include the ones listed below.
  
  As shown in Figure 1, there are various types of TIN coatings available. TIN is a universal PVD and CVD coating that can improve the hardness of tools as well as the oxidation temperature of the materials to which it is applied.
  
  By incorporating carbon into the tin, it is possible to improve the hardness and surface finish of the titanium carbonitride (TiCN) coating, which is used in aerospace applications.
  
  When cutting at high temperatures, an alumina (Al2O3) layer and these coatings, as well as a composite application of an alumina (Al2O3) layer and these coatings, can aid in the extension of tool life. Especially well-suited for cutting applications requiring dry or near-dry conditions, alumina coatings are extremely hard and durable. In contrast to TiAlN coating, which has a higher titanium content but a lower surface hardness, AlTiN coating has a higher aluminum content but a higher surface hardness. TiAlN coating has a higher titanium content but a lower surface hardness. Titanium alloys are treated with a TiAlN coating. Aluminum Titanium Nitride (AlTiN) coatings are most commonly used in high-speed machining applications.
  
  Chromium nitride (CRN) is applied as a protective coating in the fourth step:It has been determined that this coating is the most effective solution for antichip tumor applications because of its excellent antibonding properties.
  
  The application of diamond coating to cutting tools used in non-ferrous materials can result in significant improvements in the cutting performance of these tools when used in these materials. Graphite, metal matrix composites, high silicon aluminum alloys, and other highly abrasive materials are just a few of the materials that can be processed using this technology. When it comes to machining steel parts, diamond coating is not a good choice because the chemical reaction that occurs between the coating and the steel will destroy any adhesion that may have existed between the coating and the substrate during the machining process.
  
  The result is that PVD coated tools have gained market share over the last few years, and their prices are now competitive with the prices of CVD coated tools. CVD coatings are typically between 5 and 15 microns thick, with the thickness varying according to application. The PVD coating has a thickness ranging from 2 to 6 microns, depending on the application and environment. Because of the CVD coating's ability to increase tensile stress, it will be applied to the tool substrate, which is not desirable in this application. It is possible to create beneficial compressive stress in a material by applying PVD coating to it after it has been deposited on it. In contrast, when applied to metal surfaces, thick CVD coatings have been shown to significantly reduce the strength of cutting edges, according to the literature. As a result of this limitation, CVD coating cannot be used on cutting tools that require extremely sharp cutting edges, such as saws.