Problems encountered with the introduction of ion plating to large‐scale coating of tools

Abstract

Performance improvements to cutting tools through the use of ion plated coatings are discussed as they relate to the quality of tools used, the specific geometry, and the material type of tool to be coated, as well as variations inherent in the coating process. Current state of the art for mass producing coated tools and the difficulties in quality assurance of tools having different geometries and end purposes is reviewed. Numerous examples are given showing the important aspects of tool condition on tool performance, such as surface roughness, presence of burrs, oxide layers, internal segregation, and heat treatment residues. Extensive data on coated tool life, types of failure, and performance as well as the range of tool material types presently considered suitable for coating are given.