Abstract
The application of TiN-coating technology enables HSS tools of limited performance capability to be used at considerably higher material removal rates. Optimisation tests on TiN-coated tools show that the surfaces to be coated need to be manufactured to low surface roughnesses specifications and at low material removal rates. An optimum coating thickness for hobbing tools and twist drills of s = 4 μm was determined. Studies of fly cutter wear behaviour during hobbing show that face wear is substituted for flank wear as the determinant of tool life. Further improvements in performance of up to 100 % for TiN-coated hobs can be attained by using higher-alloyed substrate materials, e.g. S 10-4-3-10. In order to judge the performance capability of HSS tools with mechanically resistant coatings, machining tests are necessary, at a high cost in time and materials. The demand for a suitable short test procedure producing results which are transferable to the machining process is only inadequately met by the scratch test currently employed. An innovative short test procedure for twist drills with mechanically resistant coatings has therefore been developed. The drill lands are subjected to abrasive loads similar to those occurring in machining operations. The results enable expected tool life behaviour to be forecast.
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