Die Casting is a type of casting that uses dies to create a solid piece of metal

When working with aluminum die castings and mold blanks, it is unavoidable that the tools used in the CNC processing process will become worn over time. It is only possible to discard tools that have become excessively worn, thereby extending the tool's service life while simultaneously reducing the cost of aluminum alloy die casting in a covert manner. The coating technology will be implemented for the current cutting tools in order to increase the service life of the cutting tools while also significantly improving machining efficiency. In this article, we will discuss the causes of tool wear in aluminum die casting operations, as well as methods for reducing tool wear in these operations.

 

Tool Wear Comes in a Variety of Forms

It is common to encounter the following types of tool wear:

1 Wear on the flanks of the body2 Deterioration of the scoring surfaces3 Wear and tear on the crater

Sharp cutting edge with rounded tip on number four.

The following are five examples of cutting-edge collapses.

6 Crack on the cutting edge of technology

There have been seven instances of catastrophic failure.

The Reasons for Tool Wear Are As Follows:

Heated air and friction are manifestations of energy during the metal cutting process for aluminum casting factory or mold blanks in the die casting or mold blanks. When the tool is subjected to a high surface load, as well as the heat and friction generated by the rapid sliding of chips along the tool rake face, the machining environment becomes extremely demanding. Occasionally, the cutting force will fluctuate in both directions, which is primarily determined by the different operating conditions. In order to maintain its strength even when subjected to high cutting temperatures, the tool must possess certain fundamental characteristics, such as excellent toughness, wear resistance, and high hardness, amongst other characteristics.

Learn how to reduce tool wear and extend the life of your tools.

Currently, there is no widely accepted unified definition of tool life in the literature, which is typically dependent on different workpiece and tool materials, in addition to different cutting processes. One approach is to settle on an acceptable maximum flank wear limit as a starting point for a quantitative analysis of the end point of tool life before proceeding with the quantitative analysis.

Cutting at high speeds necessitates the continuous development of optimal tool substrate, coating, and cutting edge preparation technology, which is critical for limiting tool wear and resisting high-temperature cutting. All of these considerations, in addition to the chip breaking groove and corner arc radius that have been adopted on the indexable blade, determine the suitability of each tool for different workpieces and machining operations. Tool wear and tool life can be reduced by utilizing the most effective combination of all of these elements, which can also make the cutting process more cost-effective and dependable while also increasing productivity.

The best Coated Tools should be chosen for the job.

In addition, the coating contributes to the improvement of the cutting performance of the tool. Examples of current coating technologies include the following:

Figure 1 shows an example of a TIN coating, which 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.

Increased hardness and surface finish of the titanium carbonitride (TiCN) coating, which is used in aerospace applications, are achieved by incorporating carbon into the tin.

Alumina (Al2O3) layer and these coatings, as well as the composite application of alumina (Al2O3) layer and these coatings, can aid in the extension of tool life when cutting at elevated temperatures. Alumina coatings are particularly well suited for cutting applications that require dry or near-dry conditions. AlTiN coating, in contrast to TiAlN coating, which has a higher titanium content but a lower surface hardness, has a higher aluminum content but a higher surface hardness. TiAlN coating is used on titanium alloys. The majority of the time, AlTiN coatings are used in high-speed machining applications.

Fourth, chromium nitride (CRN) is applied as a protective coating:With excellent antibonding properties, this coating has been identified as the preferred solution for antichip tumor applications.

In non-ferrous materials, the application of diamond coating to cutting tools can result in significant improvements in the cutting performance of these tools. Some of the materials that can be processed with it include graphite, metal matrix composites, high silicon aluminum alloys, and other highly abrasive materials, to name a few. However, diamond coating is not suitable for machining steel parts because the chemical reaction that occurs between the coating and the steel will destroy any adhesion that may exist between the coating and the substrate during the machining process.

Thus, PVD coated tools have gained market share in recent years, and their prices are now competitive with those of CVD coated tools. CVD coatings are typically between 5 and 15 microns thick, depending on the application. The PVD coating has a thickness of approximately 2-6 microns, depending on the application. When applied to the tool substrate, the CVD coating will result in an increase in tensile stress, which is not desirable in this application. When PVD coating is applied to a substrate, it aids in the formation of beneficial compressive stress in the material. On the other hand, thick CVD coatings are known to significantly reduce the strength of cutting edges when applied to metal surfaces. Therefore, CVD coating cannot be used on cutting tools that require extremely sharp cutting edges, as a result of this limitation.