 Wysłany: Pią 5:40, 13 Maj 2011 Temat postu: Ultratool Carbide Tools Iowa Cutting Tools in Ch |
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| Ultratool Carbide Tools Carbide Substrate From being the first Company to introduce MicroGrain carbide to the mass-market round toot industry through the present day, Tool Alliance(D has consistently innovated new powder and grade combinations for demanding applications. We recognize that our material is the very first Significant Characteristic. By creating partnerships with a limited number of tungsten powder and cemented-carbide material suppliers, we are able to guarantee that our customers receive precision-tolerance tools ground from only the purest, finest grades available worldwide. The following photographs of Ultra-Carb@ I and Ultra-Grain@ 1 respectively demonstrate the complexity of the compound we commonly refer to as Cemented Carbide. Taken at magnification of 10,000 Xthrough an SEM (Scanning Electron Microscope), the visible grains are tungsten while the cobalt binder appears as dark shadows. The largest tungsten grains appearing in the Ultra-Carb photo are less than one micron in size. Note that these grades are two samples representing more than a dozen different substrates we use throughout our product lines, each having a particular application niche. Compared to other industry participants, you will find that Tool Alliance offers the best month-to-month and year-to-year consistency in carbide grain structure.
COMPONENT#2: The Grinding Process After selecting the best material available, Tool Alliance has perfected the manufacturing technology to optimize 100% of its physical properties. We call this process SmoothGrind@. Years in development, SmoothGrind is the result of a proprietary combination of material,cutting tools, abrasive, coolant, machine-tool, software, and grinding method technologies that produce cutting tools with superior qualitative characteristics. Sharper and longer lasting cutting edges, enhanced work piece finishes, and improved lubricity are just some of the benefits brought to you by the latest solid carbide rotary tooling advances from Tool Alliance. The following photographs display an Ultra-Toot end mill primary relief featuring SmoothGrind (left) versus a major competitor’s product (right). To fully demonstrate the difference, the Ultra end mitt is shown at double the magnification. Note the straight line of our end mitt’s primary relief in comparison to the jagged edge of the competing product. Keep in mind the competitive end mill is a very good product that has a large following, yet the difference is substantial. COMPONENT #3: The Tooling Process Alt the best physical ingredients are wasted unless they are all pulled together in a comprehensive system that maximizes their respective attributes. Tool Alliance calls this process SrroothContr1city@. Our customer base represents the leading edge of machine tool utilization, and shrink fit ready SmoothContricity ensures that optimum results can be obtained in a variety of ways; minimized run-out (TIR), industry-leading tolerances on diameter& radius, and 100% Shrink Fit Ready (SFR) shanks. Combined, these attributes allow our consumers to reach full machining potential and position the cutting tool as a systematic contributor to process consistency and repeatability. COMPONENT #4: The Edge Preparation Process Our cutting edges are literally too sharp for certain materials. For our carbide inserts and now increasingly for our solid carbide round tools, proper edge preparation can yield huge productivity improvements to “out of the box” toot application. Using a treatment we call SmoothEdge® and performed on machine tools developed in our own R&D lob, we’ve taken the mystery out of tool “break-in” and provided a consistency that can be counted on time and again. The process ranges from SmoothEdge 1, a microblosting treatment us¬ing extremely fine aluminum oxide powder (note: this procedure is standard with any coated product) to SmoothEdge 5, which adds a double cycle of honing & lubricity treatments. All five will sound and run smooth from the first cut and protect your tooling investment from unnecessary potential for chipping during your initial tooling paths. Big productivity gains can be achieved in certain applications as well due to improved chip formation and evacuation. Learn more about SmoothEdge on Page #46. COMPONENT #5: The Coating Process The challenge of finding a coating method to leverage 100% of the inherent assets of our carbide grade and grinding technologies was difficult. What we finally discovered was such a perfect fit and so logical for our product lines that we invested heavily into the process we now call SmoothCoat@. Much more than simply the standard arc-deposited PVD coating, SmoothCoat involves sputter multi-layering and a multi -step prep& post operation called Micro- Blasting. The advantages of this procedure include relieving of tensile stresses underneath the cutting edge, increased stability of the coating surface, and perhaps most importantly, elevating SmoothGrind even another notch by leveling and activating the cemented carbide substrate. The result is a smooth, shiny, tough, and durable surface that can withstand tomorrow’s machining requirements and outlast competitive coatings. Additionally, we’ve made it a standard feature on thousands of our standard catalog items. Our coating services are performed within our own factories for quality & extremely quick turnaround times. |
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