CAT.DLC. 06/19
High Accuracy & High Efficiency Coating for Cutting of Aluminum Alloys
D iamond -L ike C arbon (DLC)
First & Only U.S.A. Based DLC Coating Service Located at Sumitomo Electric Carbide Manufacturing in New Berlin, Wisconsin
R egrinds S umitomo S tandard C ustom T ooling R e -C oating
DLC Coatings are less likely to cause aluminum adhesion and have a lower friction resistance, which smoothly discharges cutting chips. The tools coated with DLC had lower cutting forces compared to a normal cemented carbide tool in both wet and dry conditions. The Arc PVD Method forms DLC films and do not contain hydrogen. They are hard thin films with a hardness second to diamond. They are used for tools for cutting aluminum alloys and molds, and are effective in preventing adhesions of soft metals and resins, improving processing accuracy and extending tool life. Arc PVD Method The cathode arc PVD (Physical Vapor Deposition) method forms a DLC film on the surface of a substrate by generating a continuous vacuum charge on the surface of a solid graphite cathode to efficiently generate carbon ions. This process features easy formation of hard hydrogen-free DLC films that contain more diamond and less graphite because of the high vaporization and ionization rates of graphite. D iamond -L ike C arbon C oating P rocess Diamond-Like Carbon (DLC) film is an amorphous film which main composition is carbon with lubricity and chemical stability. It is a unique hard thin film that features high-hardness, superior tribology properties, and excellent adhesion resistance. DLC films have been used to reduce fuel consumption of automobiles by reducing friction loss and are also used as a coating of cutting tools for aluminum alloys that have been widely used for automobile weight reduction.
Arc Vapor Source - Graphite Target
DLC Characteristics
Rotating Holder
Sumitomo DLC Conventional
>
>
0.01μm 59GPa 0.1~0.5μm
0.07μm 37GPa 1.2μm
Thickness Hardness Ra
>
Exhaust
ALUMINUM MARKET TRENDS
Automotive
Aluminum Alloys use in the automobile industry marks the highest growth from all other aluminium applications and remains the fastest growing automotive material over competing materials due to the increased demand of lightweight materials and its implications in improving fuel economy, carbon neutrality and high performance. The mechanical properties of aluminium, high strength stiffness to weight ratio, good formability, good corrosion resistance, and recycling potential makes it the ideal candidate to replace heavier materials in the car to respond to the weight
reduction demand within the automotive industry. This important material shift in the automotive sector is driving the demand for aluminium and also for the equipment and technology suppliers who are contrib- uting towards quality and process improvement in aluminium producers all through the value chain.
Aircraft & Aerospace
Aluminum was the leading matierial in the aerospace industry for many years with as much as 70% of an aircraft being made from aluminum. Today, less than 25% of an aircraft uses aluminum while other light- weight compositites, alloys, and carbon-fibers are being applied for non-critical structural areas. While the amount of aluminum in an aircraft have been in decline, the use of the material has been steadily increasing over the past 20 years. Composite materials use in aircrafts, including carbon fiber reinforced polymers (CFRPs), have been driven by the performance improvements offered compared to conven- tional aluminum alloys, including the ability to reduce weight and maintenance costs. In cases that
carbon fiber reinforced polymers are unsuccessful or are not cost friendly, aluminum has beenable to gain momentum with the help of Titanium aluminide (TiAl) and aluminum
lithium (Al-Li). These alloys have been growing in the aerospace industry due to their low density, higher strength, and fatigue and corrosion resistance. The high stability of these alloys makes them ideal for use in mechanical components, which also benefit from aluminum’s high electrical conductivity. Most commonly utilized in fuselage, wing, and supporting-structure construction, aluminum offers a range of benefits for both aircraft and space flight engineering.
E ndmill S olutions
ASM4000DL
SNB Ball Nose Endmill
ASM 2 Flute and 4 Flute Endmills
ø2.0mm - ø16.0mm
ø2.0mm - ø16.0mm
DLC coating has a low friction coefficient resulting in an advantage of reduced friction on non-ferrous materials.
M illing S olutions
WAX
WAX Shoulder Milling Cutter
WRCX WaveRadius Mill Series
WEX Wave Mill Series
ø0.75in - ø5.00in
ø1.00in - ø6.00in
ø0.50in - ø8.00in
Adhesion Resistance
Diamond Coated Uncoated Excellent adhesion resistance and reduced cutting force
DLC Coated
Material: ADC12 Machine: Makino V55 Tool: WEX3032E, AXET170504PEFR-S-DL1000 Cutting Conditions: 984 SFM, f=0.0059in/t, a p =a e =0.197in, L-29.5ft
D rilling S olutions
NHGS
Low Cutting Force
DLC Coating Effectiveness
1,800
Drill: MDW0800NHGS5 (ø8.0) Material: A7075-T6, Vc= 984 SFM (300m/min), Coolant set at 300psi • 67% Reduction in thrust provides higher efficiency drilling • Apply 3-5 Times the feed rate vs. uncoated drills • Regrind & Recoating provides almost the same thrust force as a brand new drill
Uncoated New DLC Coated New
Regrind & Recoat Regrind Only
1,500
67% Reduction
1,200
900
600
300
0
0.1
0.4 Feed Rate: f (mm/rev) 0.6
1.0
DLC Multidrill Variety
High Accuracy
High Efficiency
NHRF Type
NHMF Type
NHGS Type
*Made to order
*Made to order
2 Flutes
3 Flutes (10° Helix)
3 Flutes (30° Helix)
Cast Hole
Cast Hole Solid Hole
Solid Hole
Purpose: Reduce Cycle Time by combining Rough & Semi-finish • Achieve reduced cost per unit vs. PCD Reamer
Purpose: Reduce Cycle Time • High efficiency & high accuracy • Achieve reduced cost per unit vs. PCD Drill Performance: • Low Cutting Force • H8 Hole Tolerance • Roundness 15μm or less • Position ø0.3 or less
Purpose: Reduce Cycle Time • Super high efficiency vs. Straight Flute Drill • Achieve reduced cost per unit vs. PCD Drill Performance: • Super Low Cutting Force • High Feed Drilling Available (Max : D x 10%)
Performance: • High Rigidity • H7 Hole Tolerance • Roundness 5μm or less • Position ø0.25 or less
Improved Chip Control
Excellent chip evacuation with no curling on the body
Straight Flute PCD Drill
NHGS Series
Achieves reduced cutting force and surface roughness Wear Resistance & Burr Uncoated Drill (924 holes) DLC Coated Drill (1,000 holes)
Material: 7075 Aluminum Tool: MDW0800NHGS5 Cutting Conditions: 984 SFM (300m/min), 11,927 RPM,
0.0039 IPR (0.1mm/rev), 46.51 IPM (1,181mm/min)
Extended Tool Life
Material - Aluminum Alloy A380
NHGS
Competitor
Tool
MDW0895NHGS8
- -
Grade
DL1300
Diameter DC (inch)
8.95
8.95
RPM (Max) Speed (SFM)
10,000
10,000
922
922
Feed (IPR)
0.0118” Through
0.0094” Through
Coolant
Cut Time/ Part (min) Number of Parts/ Edge Est. Tool Usage (Annually) Annual Part Production
0.14
0.17
17,500
8,000
9
20
1,100,000 - Results : Tool life increased 119% and achieved 112.5% more parts per edge
R econditioning S olutions
Bring new life into your used tools by Sumitomo, or our competitors, by sending them to Sumitomo Electric Carbide Manufacturing for a quality regrind, and recoat in our brand new DLC coating chamber. Protect your investment and get the most out of what you put in by further enhancing the productivity of your tools. A Sumitomo certified regrind will reduce your cost of production and waste - improving your profitability.
*For more information about regrinds, please contact your local sales representative
R ecommended C utting C onditions (I nch )
Type
Dia. DC (inch)
Parameter
Aluminum Casting
Wrought Aluminum
NHGS
262 - 460 - 656
262 - 394 - 656
V c SFM
ø0.118" ~ ø0.236"
0.008 - 0.016 - 0.024
0.008 - 0.014 - 0.020
f IPR
328 - 590 - 820
328 - 557 - 820
V c SFM
ø0.240" ~ ø0.394"
0.016 - 0.025 - 0.047
0.012 - 0.024 - 0.043
f IPR
394 - 590 - 820
394 - 525 - 820
V c SFM
ø0.398" ~ ø0.708"
0.016 - 0.027 - 0.047
0.012 - 0.025 - 0.043
f IPR
NHMF
262 - 460 - 656
262 - 394 - 656
V c SFM
ø0.157" ~ ø0.236"
0.010 - 0.016 - 0.024
0.010 - 0.014 - 0.024
f IPR
328 - 590 - 820
328 - 557 - 820
V c SFM
ø0.240" ~ ø0.394"
0.012 - 0.022 - 0.032
0.012 - 0.020 - 0.032
f IPR
394 - 590 - 820
394 - 557 - 820
V c SFM
ø0.398" ~ ø0.708"
0.016 - 0.024 - 0.039
0.016 - 0.022 - 0.032
f IPR
NHRF
262 - 492 - 656
262 - 426 - 656
V c SFM
ø0.197" ~ ø0.236"
0.006 - 0.008 - 0.012
0.006 - 0.008 - 0.012
f IPR
328 - 656 - 820
328 - 590 - 820
V c SFM
ø0.240" ~ ø0.394"
0.008 - 0.010 - 0.014
0.008 - 0.010 - 0.014
f IPR
394 - 656 - 820
394 - 590 - 820
V c SFM
ø0.398" ~ ø0.787"
0.008 - 0.011 - 0.014
0.008 - 0.011 - 0.014
f IPR
394 - 656 - 820
394 - 590 - 820
V c SFM
ø0.791" ~ ø1.181"
0.008 - 0.012 - 0.014
0.008- 0.012 -0.014
f IPR
R ecommended C utting C onditions (M etric )
Type
Dia. DC (mm)
Parameter
Aluminum Casting 80 - 140 - 200 0.2 - 0.4 - 0.6 100 - 180 - 250 0.4 - 0.65 - 1.2 120 - 180 - 250 0.4 - 0.7 - 1.2 80 - 140 - 200 0.25 - 0.4 - 0.6 100 - 180 - 250 0.3 - 0.55 - 0.8 120 - 180 - 250 0.4 - 0.6 - 1.0 80 - 150 - 200 0.15 - 0.2 - 0.3 100 - 200 - 250 0.2 - 0.25 - 0.35 120 - 200 - 250 0.2 - 0.28 - 0.35 120 - 200 - 250 0.2 - 0.3 - 0.35
Wrought Aluminum 80 - 120 - 200 0.2 - 0.35 - 0.5 100 - 170 - 250 0.3 - 0.6 - 1.1 120 - 160 - 250 0.3 - 0.65 - 1.1 80 - 120 - 200 0.25 - 0.35 - 0.6 100 - 170 - 250 0.3 - 0.5 - 0.8 120 - 170 - 250 0.4 - 0.55 - 0.8 80 - 130 - 200 0.15 - 0.2 - 0.3 100 - 180 - 250 0.2 - 0.25 - 0.35 120 - 180 - 250 0.2 - 0.28 - 0.35 120 - 180 - 250 0.2 - 0.3 - 0.35
NHGS
V c m/min f mm/rev V c m/min f mm/rev V c m/min f mm/rev V c m/min f mm/rev V c m/min f mm/rev V c m/min f mm/rev V c m/min f mm/rev V c m/min f mm/rev V c m/min f mm/rev V c m/min f mm/rev
ø3.0 ~ ø6.0
ø6.1 ~ ø10.0
ø10.1 ~ ø18.0
NHMF
ø4.0 ~ ø6.0
ø6.1 ~ ø10.0
ø10.1 ~ ø18.0
NHRF
ø5.0 ~ ø6.0
ø6.1 ~ ø10.0
ø10.1 ~ ø20.0
ø20.1 ~ ø30.0
Sumitomo Electric Carbide, Inc.
For more information about our new DLC Coating Chamber, please contact Engineering@sumicarbide.com
Sumitomo Electric Carbide, Inc. 1001 E. Business Center Drive Mount Prospect, IL 60056-2181 P.O. Box 545, Mt. Prospect, IL 60056-0545
Phone: (800) 950-5202 Phone: (847) 635-0044 Fax: (847) 635-9335
Sumitomo Electric Carbide Manufacturing, Inc 5635 S. Westridge Drive New Berlin, WI 53151
CAT.DLC.06/19
www.sumicarbide.com/DLC
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