26/10/2007
CERATIZIT develops an innovative multi-phase SiALON CTI3105
Faster production process and longer tool life with the hardest SiALON in the world-market! |
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Technical article written by Dr. Uwe Schleinkofer, head of the development department cutting tools at CERATIZIT
In order to be able to carry out highly efficient cutting processes the demands on the tools and inserts are continuously increased. Both higher cutting speeds and feed rates will have to be achieved. In addition to these trends, properties such as reliability combined with maximum heat resistance and chemical stability play an ever increasing important part in the field of the cutting materials. In particular this applies to dry machining. CERATIZIT is facing this trend by developing high-performance inserts in all materials. The extensive competence of the CERATIZIT group in the sector of HSS produced with powder metallurgy, carbides, cermets, silicon nitride and mixed ceramics, as well as ultra-hard cutting materials like CBN and PCD have now been completed through the new multi-phase SiALON CTI3105.
For the very first time: high-performance cutting for super-alloys
The concept ’SiALON’ stands for an individual ceramic material group, which is based on silicon nitride (Si3N4) and includes other components like aluminium and oxygen. CTI3105 is the hardest and thus most wear resistant SiALON in the world which is provided by a specifically adapted micro-structure of the grain shape (see picture) and unlike the notably softer SiALON materials of our competitors, does not loose toughness.
The long grain structure of some phases in the ceramic composite material required for the hardness and wear resistance of this kind has been achieved with a specific composition and sinter-technology specifically developed for this grade. Also the new CTI3105 is characterized by maximum chemical stability at extremely high temperatures. The combination of high hardness and good toughness as well as chemical stability and heat resistance for the first time allows HPC processes (High Performance Cutting) in cast iron machining and difficult-to-machine materials like super alloys.
Faster production process, longer tool life
With this new generation of cutting tools it is possible to increase both the cutting speed and feed rate without reducing the reliability of the machining process. The increased cutting speed possible with the new multi-phase SiALON CTI3105 from CERATIZIT reduces the production cycle by up to 20%. Thanks to the excellent wear resistance even with high cutting speed and applying ceramic materials, tool life may be increased up to 25%.
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Specials
