CemeCon's Ultra-thin and Smooth HiPIMS Coatings for Micro Cutting
Tool coating solution provider, CemeCon AG introduced ultra-thin and extremely smooth HiPIMS coatings for small and the smallest tools that provide the decisive advantages in difficult to machine hard materials especially, in the fields of electronics and medical technologies. In the HiPIMS process the coating errors such as droplets cannot occur at all with this unique technology.
The results are extremely smooth coatings that also meet the low tolerances of miniature production. The coatings are also incomparably adhesive, fine-grained, very dense morphology, a lower residual stress, high thermal stability, as well as hard and tough at the same time. These perfectly smooth surfaces on cutting tools minimize both friction and built-up edges, while at the same time shortening the contact time between chip and tool. The heat input as well as oxidation wear is also substantially reduced, which contribute to long service life – even with dry and HSC machining. Ultra-thin coating approximately 1 μm (almost) has no impact on the filigree geometry of the micro tools. HiPIMS allows very thin and thick layers down to 12 µm. Thanks to the process, the cutting edges are also not unintentionally rounded. Thereby HiPIMS enables a homogeneous layer growth on complex tool geometries around the cutting edge. This ensures an even coating thickness distribution within very narrow tolerances, which are required for micro cutting.
The composition of the coating material has a great influence on the cutting process. InoxaCon® – one of the HiPIMS coating materials, offers tool manufacturers primarily in miniature production a decisive advantage, like in the machining of chrome-cobalt alloys for implants used in medical and dental technology. The smooth surface of InoxaCon® eliminates friction during machining. The very good coating properties allow the use under the toughest conditions with low coating thicknesses of, such as, 1.5 µm. The cutting edges, therefore remain so sharp that feed and cutting speed can be selected for minimum cutting forces and thus better machining results. It also prevents work hardening and ensures process stability. The modified tools with a coating based on an InoxaCon® coating specification produce excellent surfaces during milling and eliminates polishing work thus shortening process times and ensuring more efficient automated production.
“With our premium engineering service, the focus is on the tool in its customer-specific form and function. Especially with new geometries, innovative tool concepts and special applications – such as tools for micro cutting – the path is increasingly leading to this fully engineered premium coating. In close cooperation with the tool manufacturer, we project a coating solution that is precisely tailored to the tool and application requirements,” explains Marc Semder, Sales Manager, CemeCon.
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