Figure 4 Correspondence between thickness of alumina coating and crack

Test conditions:

Workpiece material GG26Cr

Dry cutting

45° main angle face milling cutter with diameter of 125mm

SEHW1204AFN milling insert

Vc=477 m/min, fz=0.2 mm

Ap=3 mm, ae=110 mm

John Deere is a US company that manufactures agricultural vehicles, construction vehicles, and engines and their components. Some of their engine cylinder heads are made of cast iron. They used a famous 6K5A06R01 milling cutter known as a milling tool for finishing. The cutter with a diameter of about 152mm uses 10 general blades (LPE324-03) and 2 polishing blades (LPE324-0 wipers). The blade material is 722. With this milling cutter, they were machined at a cutting speed of about 274 m/min and a feed rate of 0.13 mm/Z at a feed rate of 873 mm/min. With Walter's tiger blade, the cutting speed is increased to 305 m/min, the feed rate is maintained at 0.127 mm/Z, the feed rate is increased to 965 mm/min, and the wiper blade is not required for machining with Walter tools. John Deere's metalworking experts were very pleased that the Tiger Blades became their only logical choice in the project, for which they purchased seven Walter milling cutters. Because of the use of tiger blades, their tooling costs were reduced by 55%, and the overall processing cost was reduced by approximately 6.5% due to reduced tooling costs and increased processing efficiency. The use of tiger blades reduces their processing costs, reduces tooling costs, improves machining quality and simplifies tool management.

What makes the tiger blade provide higher cutting speeds than rough in the rough cast iron? Walter's technical department made its own explanation. They said that first of all, plating technology played a major role. Practice has shown that black alumina coating is the best choice for processing cast iron, especially for rough cast iron. Moreover, we can see from Figure 4 that the thickness of the alumina coating is inversely proportional to the occurrence of comb cracks. However, since the thick plating layer will damage the bonding force of the plating layer, the conventional plating of the tool is generally thin. The researchers of Walter Tiger Blades have developed a special intermediate layer through a large number of research experiments, which improves the bonding strength of the coating and allows the thickness of the coating to be increased, so that the more durable alumina coating is fully utilized. At the same time, the cemented carbide substrate has been further improved to make it more wear resistant. The high cutting speed and process reliability of the tiger blade is largely due to the combination of the alumina coating with a modified tungsten carbide matrix through a special intermediate layer. It is worth noting that the results of the test at Tuebingen, where the Walter Group headquarters is located, show that the improvement of the wear resistance and the mitigation of the comb-like cracks have greatly improved the cutting performance of the tiger blade. This is why tiger blades have superior wear resistance when machining cast iron.

Black and gold color combinations are also highly practical, says Joerg Drobniewski, who is involved in Tiger Blade development at Walter. "There is no doubt that cemented carbide inserts with alumina coating should be preferred when roughing cast iron. The main drawback is that the black coating makes the traces of wear illegible.” According to Joerg Drobniewski, this is the magic weapon for the tiger blade: “With the black rake face and the golden flank, we can effectively identify the tool. abrasion".

With a tiger blade for roughing cast iron, Walter has made a huge revolution. Often the internationally renowned tool companies have some competitive advantages, and our case comparisons show that in these cases our specific products are more suitable than the competitors that the customer originally used. At least in practical applications, the Tiger Blade has achieved a dramatic development in the processing of cast iron carbide inserts, achieving the cutting efficiency and service life previously only possible with ceramic inserts, with significant competition in terms of economics. Advantage.

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