CARBIDE INSERT QUOTATION,INDEXABLE CARBIDE INSERTS,CARBIDE INSERTS

Face milling cutters are essential tools used in the machining industry for various applications, including roughing, finishing, and contouring operations. The efficiency and performance of face milling cutters depend not only on the design and quality of the cutter itself but also on the type of coating applied to the cutting edges. Different coatings can significantly impact the effectiveness and longevity of face milling cutters. Let's explore how various coatings affect the efficiency of face milling cutters:

Titanium Nitride (TiN) Coating: TiN coating is a popular choice for face milling cutters due to its excellent wear resistance and high thermal stability. This coating helps reduce friction and heat buildup during the cutting process, thus improving the tool's performance and extending its lifespan. TiN-coated face milling cutters are ideal for high-speed machining of steel, cast iron, and other ferrous materials.

Titanium Carbonitride (TiCN) Coating: TiCN coating offers enhanced hardness and abrasion resistance compared to TiN coating. It is suitable for face milling APMT Insert cutters used in machining applications that require high cutting speeds and feed rates. TiCN-coated cutters can effectively withstand the heat and wear that occur during aggressive cutting operations, making them a reliable choice for difficult-to-machine materials like stainless steel and high-temperature alloys.

Aluminum Titanium Nitride (AlTiN) Coating: AlTiN coating provides superior oxidation and thermal shock resistance, making it well-suited for face milling cutters used in high-temperature machining environments. This coating also offers improved lubricity and chip evacuation, resulting in smoother cutting and better surface finish. AlTiN-coated face milling cutters are commonly used for machining hardened steels, nickel-based alloys, and titanium.

Diamond-Like Carbon (DLC) Coating: DLC coating is known for its exceptional hardness, low friction, and high chemical inertness. Face milling cutters with DLC coating exhibit excellent wear resistance and can effectively machine a wide range of materials, including hardened steel, aluminum, and composites. DLC-coated cutters are particularly beneficial for applications that involve abrasive materials and high-speed machining.

Overall, the choice of coating for face milling cutters depends on factors such as the material shoulder milling cutters being machined, cutting conditions, and desired tool life. By selecting the right coating, machinists can optimize the efficiency and performance of their face milling cutters, leading to improved productivity and cost savings in the long run.

The KBDM polycrystalline diamond (PCD) face milling system from Kennametal is designed for high-volume machining, with standard sizes ranging from 2.5" to 8.0" (63 to 200 mm) and cutter diameters ranging to 21.5" (550 mm). According to the company, these wide diameters enable the machining of large components, such as automotive components, in a single pass. Options for integral shank bodies, HSK mounting and left-hand cutter rotation are available, as well as special edge preparations and nose radii.  

This face milling platform uses a fine-pitch aluminum body with wedge-style clamps and adjustable pockets. A variety of PCD inserts are available, from mini-tips for light finishing cuts to full face wipers, standard cartridge inserts, and ½" (12.7-mm) axial cutters Threading Inserts for heavy roughing and shoulder cutting.

In the case of automotive manufacturing, the company reports that this tool system can achieve finishes of 2 to 3 microns Ra and long tool life. Additionally, Kennametal has developed two PCD grades to meet the needs of automakers using their own proprietary aluminum alloys. The KD1400 uses small diamond grains and offers good chipping resistance and wear attributes, while the KD1425 uses large diamond grains, improving abrasion resistance and thermal stability and only slightly lower performance where chipping is a concern. Both are capable of very high cutting parameters, the company says; depending on the alloy and setup rigidity, Kennametal recommends an initial cutting speed of 3,280 fpm (1,000 m/min.) and feed rates of 0.004" per tooth (0.01 mm), although higher values Shallow Hole Indexable Insert are possible.