B000GP015G

A new generation of PVD coatings

1

PVD coatings (Physical Vapour Deposition)PVD is applied to many tools, including drills, end mills, rotating tool inserts, and inserts for diffi cult-to-cut materials.As the coating temperature of PVD is lower (around 700°) than that of other coatings applied to the cutting tools, damage to a substrate during coating is reduced. This maintains the toughness of even sharp edges and a coated layer with superior wear resistance and heat resistance is formed using the latest coating technologies. PVD is applied to tools that require sharp cutting edges and shape maintainability.

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Next-generation PVD

In the past, almost all coating materials have been either TiN or TiCN for improved wear resistance. However, with the rapid development of PVD coating technology, (Al, Ti) N coating with thermal stability has become the most popular coating material in recent years and achieves high quality and performance for the machining of hardened steel and stainless steel, which have been diffi cult-to-cut materials.Through the use of Al-Cr-Ti based components and optimized layer coatings, Mitsubishi Materials continues to take a fresh approach to enable a wide range of different machining applications.

It has already been 30 years since the PVD coating was developed. To satisfy our customers demand for achieving highly efficient machining, Mitsubishi Materials has developed “MIRACLE SIGMA,” which can be used together with products utilizing Mitsubishi’s new PVD coating technology by combining our latest coating technologies with our geometry designing technologies.

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PVD

P P10

P20

P30

P40

PVD

S S10

S20

S30

S40

PVD

M M10

M20

M30

M40

P M S

MP6120/MP6130 MP7130/MP7140 MP9120/MP9130

MP6120

MP9120

MP9130

MP7130

MP6130

MP7140

New PVD Coated GradesMP6100/MP7100/MP9100

ISOCoated Carbide

Ste

el

ISOCoated Carbide

Heat

Res

istan

t Allo

y • T

i Allo

y

ISOCoated Carbide

Sta

inle

ss S

teel

PVD accumulated coating(Each damage measures)

Excellent welding resistance due to low coefficient of friction

Special cemented carbide substrate

Wide range of grades for specifi c materialsMIRACLE SIGMA accumulated Al-Ti-Cr-N based PVD coating

Tool wear

and Damage

Steel Stainless Steel Heat Resistant Alloy • Ti Alloy

Thermal Cracks Notching Welding by Chipping

FeaturesImproved thermal conductivity Improved layer toughness Low affi nty at high temperature

Shape

4

S55C SUS304 Ti-6Al-4V

P 0.4M 0.5S 0.3

0.7 0.7 0.7

TOUGH-Σ Technology

P

M

S

2700

1200

1100

1000

900

800

7002800 2900 3000 3100

Hardness (Hv)

Conventional

Oxi

datio

n te

mpe

ratu

re (C

º)

Wear resistance

Hea

t res

ista

nce

A fusion of the separate coating technologies; PVD and multi-layering realises extra toughness.

Multi-layering of the coating prevents any cracks penetrating through to the substrate.

*Graphical representation.

*Graphical representation.

Work Material Grade

Coeffi cient of friction

Measured at 600 degress

Carbon Steel, Alloy Steel MP6100Stainless Steel MP7100

Titanium Alloy, Heat Resistant Alloy MP9100Conventional

MP6100MP7100MP9100

The new technology Al-(Al, Ti)N coating provides stabilisation of the high hardness phase and succeeds in dramatically improving wear, crater and welding resistance.

Best layer of each workpiece

(Al,Cr)N

Tough! Thermal Cracks

TiN

Tough! Notching

CrN

Tough! Resistant Chipping

Base layer High Al-(Al, Ti)N

Dramatically improving the heat and wear resistance!

Excellent welding resistance due to low coeffi cient friction!

PVD accumulated coating

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WSX445

WSX445

Anti Fly Insert mechanism (AFI)

New face milling cutter with innovative double sided insert.Perfect balance between high effi ciency and ease of use.

Designed to control abnormal insert breakage and body damageThe unique conical insert seat and Anti Fly mechanism (AFI) hold the insert securely. The outer edge of the insert is not in contact with the body, thereby preventing damage if sudden fracturing occurs.The thick insert negates the need for a shim.

Through Coolant HolesThrough coolant holes are standard for cutters under 160mm diameter.Improves chip discharge and prevents chip welding.

Single sided insert type

Double sided insert type

Cos

t Per

form

ance

Low resistance

Low cutting resistance, double sided insert face mill for general machining

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WSX445

26°*

31°* 5°─ -5°*

Double sided Z Geometry

Axial centre line

Cutting edge

Unique insert minimizes chatter and vibrationZ Insert Geometry provides low cutting resistanceMitsubishi Materials’ proprietary “Double sided, Z Geometry” insert features a sharp cutting edge with low cutting resistance by utilizing features of both conventional positive and negative rake inserts.

For a sharper cutting edge

For a sharper cutting edge

For higher edge strength

Double sided insert

Single sided insert

Double sided insert

Axial centre line Axial centre lineConventional positive insert Conventional negative insert

*Rake angle mounted an insert.

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Point

Exchangeable Head End Mills

iMX End Mill Series

The iMX series is a revolutionary end mill system that enables effi ciency, high accuracy and rigidity by combining the advantages of both solid carbide and indexable end mills.Security and rigidity close to that of a solid type end mill because the clamping faces are all carbide.Excellent for reduced inventory over a variety of applications due to the exchangeable head.

Available with internal coolant

Special steel screw joint

Mono-block carbide holder

PointDouble face contact type

(Taper + End face)

Steel Steel Cemented carbide

Cemented carbide

8

0.3

0.25

0.2

0.15

0.1

0.05

0

100

50

0

iMX

0 0.10 0.12 0.14 0.16 0.18 0.20

EP7020

EP6120

0 2 4 6 8 10 12 14

7.5m 12.5m

Tool life comparison when machining fl at surfaces in Inconel 718EP7020 is a new grade that enables extended tool life when machining diffi cult-to-cut materials.

Work materialHolderHeadRevolutionCutting speedFeed rateDepth of cutProtrusion lengthCutting modeMachine

: Inconel718(43HRC): IMX12-U12N041L100C: IMX12B4HV12012: n=1700min-1

: vc=28m/min: vf=350mm/min (fz=0.05mm/tooth) : ap=0.6mm ae=1.2mm: 65mm: Down cut, Wet (Emulsion): Vertical M/C(BT40)

Cutting length (m)

Competitor B Competitor A

iMX

Max

. Flan

k wea

r at D

.O.C

line

(mm

)

Highly versatile grades

Comparison of tool rigidityThe double face contact of the carbide head and carbide holder gives an increase in rigidity of 30%.

competitorSolid End Mill iMX

Rig

idity

(%)

62mm(i3D)

Loadø20

Strength comparison when slot machining titanium alloyThe reliability of the screw fastening is signifi cantly improved when compared to competitors that employ only steel fastenings. It is also able to cope with high cutting loads.

Work materialHolderHeadRevolutionCutting speed

: Ti-6Al-4V(32HRC): IMX20-U20N030L090C: IMX20C4HV200R10021 : n=1100min-1

: vc=69m/min

Feed rateDepth of cutProtrusion lengthCutting modeMachine

: fz=Above (Expansion): ap=10mm, ae=20mm: 72mm: Wet (Emulsion): Vertical M/C(BT50)

Feed per tooth (mm/tooth)

Competitor A

Competitor B

Breakage at the screw joint

Suitable for high feed milling of steel.

Suitable for milling aluminium.ET2020 (Uncoated)

Breakage at the screw joint

ZERO-μSurface

Smoothed surface“ZERO-μ Surface”

Newly developed(Al, Cr)N group coating

Super-fine particle, super-hard base

material

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VQ-MHV

600

0

(N)

SMARTMIRACLE ®Vibration Control End Mills for Machining Diffi cult-to-Cut Materials

SMART MIRACLE® Coating

SMART MIRACLE coating

Conventional coating

Conventional coating

ZERO-μ SurfaceWith the unique ZERO-μ Surface, the cutting edge retains its sharpness. While previous technologies often resulted in diminished sharpness, the ZERO-μ Surface achieves both smoothness and sharpness, as well as longer tool life.

Smart Miracle end mills have been treated with a newly developed (Al, Cr)N group coating which delivers substantially better wear resistance. The surface of the coating has been given a smoothening treatment resulting in better machined surfaces, reduced cutting resistance and improved chip discharge. This is the next generation of coated end mills that delivers long tool life when machining stainless steels and other diffi cult-to-cut materials.

SMART MIRACLE coating

Work materialEnd millSpindle revolutionCutting speedFeed rateDepth of cutProtrusion lengthCutting modeCoolantMachine

: SUS304: VQMHVD0600(ø6): n=2,650min-1

: vc=50m/min: vf=320mm/min(0.03mm/tooth): ap=6mm: 20mm: Down cut: Emulsion: Vertical M/C (BT50)

Conventional

Cuttingresistance

reduced by more than 20%

Comparison of cutting resistance

Smoothed surface“ZERO-μ Surface”

Newly developed(Al, Cr)N group coating

Super-fine particle, super-hard base

material

ZERO-μSurface

ZERO-μSurface

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MSplus

MSplus MSplus

MS plus (AlTi)N (Al,Cr)N

3,200 2,800 3,100

1,100 800 1,100

100 80 80

10

20

30

4050

60708090100110

120130

140

150

160

170

180 0

3.01

03.

005

3.00

02.

995

2.99

0

2.99

02.

995

3.00

03.

005

3.01

0

10

20

30

40

0

2.99

02.

995

3.00

03.

005

3.01

0

Micro-grain cemented carbide substrate

(Al,Ti, Cr) N Multilayer coating

Seamless cutting edge End cutting edge geometry

Higher wear resistance than conventional products

Excellent wear resistance allows a wide range of applications.

Radius tolerance R±0.005mm

Good surface fi nishes possible even when simultaneously cutting with end and side edges; for example on drafts of dies and moulds.

Sharp but strong cutting edge enables good surface fi nishes.

Sharp edges leave a uniform fi nish.

A dull edge leaves an undefi ned fi nish.

Suitable for fi nishing

<Cutting Condition>Work material : SKD61(HRC38 heat treated steel)Machine : Tapping center (BT20)Cutting Fluid : External emulsion

Carbide end mills

The improved end geometry provides increased sharpness and wear resistance when compared to conventional products.

Hardness (HV)

Oxidation Temperature (°C)

Adhesion (N)

Application Examples

Conventional

Conventional

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DP1020

MVE/MVS

1000

800

2750 2800 2900

Hardness (Hv)

Oxi

datio

n te

mpe

ratu

re (C

º)

Drill SeriesWSTAR

With accumulated Al-Ti-Cr-N based PVD coating

New coated grade DP1020The newly developed DP1020 grade offers excellent wear resistance and reduced friction for longer tool life and a versatile range of applications.

Reduced margin wear DP1020 has excellent wear resistance properties and therefore reduces the amount of material that needs to be removed when re-grinding.

Margin wear after 57m machiningCoventional A

Minor Deep wear marks Wide wear marks

Coventional B

<Cutting conditions>Work material : S50CCutting speed : 100m/minFeed : 0.2mm/revW.S.O (External coolant)

New Generation Solid Carbide Drills

12

60.000

48.000

36.000

24.000

12.000

0.0000

MVS

MVE

Coolant fl owspeed increase Velocity (m/s)

Conventional

FluteFlute

Cutting edgeCutting edge

Coolant hole

TRI-cooling Technology®

ZERO-μ Surface

New wavy cutting edge

The unique coolant hole geometry (on drills over ø6) increases the rate of coolant fl ow for improved cooling effect and chip removal.

Our unique smooth surface technology reduces cutting resistance and offers excellent chip evacuation.

The unique wavy cutting edge provides excellent sharpness and rigidity and helps to control wear at the periphery.

CoventionalComparison of wear at the cutting edge periphery (After 57m machining)

<Cutting conditions>Work material : S50CCutting speed : 100m/minFeed : 0.2mm/revW.S.O (External coolant)

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BC8110

BC8110

Peeling of the coating is prevented by improving welding resistance.

Improved wear and chipping resistance.

Improved adhesion to the CBN surface provides increased peeling resistance.

Prevention of welding

TiAlSiN Coating

TiAlN Coating

Newly developed special ceramic coating

Coated CBN Grade for High Hardened Steel Turning

Cutting resistanceForces dispersed in a linear direction can cause sudden fracturing.

Forces dispersed radially help to prevent sudden fracturing.

Cutting resistance

Conventional

CBN sintered body“Ultra Micro-particle Binder”

Dispersal of the new Ultra Micro-particle Binder in BC8110 prevents linear crack development that can cause sudden fracturing.

The newly developed “Ultra Micro-particle Binder” prevents sudden fracture

Medium GrainCBN

Binder macroparticles

Micro Grain CBN

Longer tool life with a coated CBN grade when turning hardened steels.

“Ultra Micro-particle Binder”

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MP9005MP9015

MP9005/MP9015

S05 MP9005

S15 MP9015

3000

2000

1000

25 50

PVD coated grade

ISO Turning Inserts for Diffi cult to Cut Materials

The new technology high Al-rich (Al,Ti)N single layer coating provides stabilisation of the high hardness phase and succeeds in dramatically improving wear, crater and welding resistance.

ISO Grade Grade Concept Application

Top-quality grade focusing on wear resistance Heat Resistant AlloyFinish-Medium Cutting

First recommendation for general applications Heat Resistant AlloyMedium-Rough Cutting

Har

dnes

s of

coa

ting

(Hv)

Soft phaseHigh hardness phase

High Al and conventional coating comparison

Al content (at%)

Conventional technology

New technologyHigh Al-rich (Al,Ti)N Conventional

Substrate

Substrate

P M S

P M S S

P M N S P M N S H

SP M K N S H H

Screw-on Insert type Shoulder Milling Cutter

Screw-on Insert type Face Milling Cutter

Multi-functional Indexable Cutter

High Feed Radius Milling Cutter

For Machining of Aluminium and Titanium Alloys

For Titanium Alloy Milling

Carbide End MillsVibration Control End Mills for Machining Diffi cult-to-Cut Materials

Exchangeable Head End Mills

New Generation Solid Carbide Drills

ISO Turning Inserts for Diffi cult to Cut Materials

Only MVE

≤55HRC

ASX445

ASX400

APX3000APX4000

AJX AXD4000VFX

iMX MS plus

SMART MIRACLE®

MVE/MVS MP9005MP9015

MITSUBISHI MATERIALS CORPORATIONOverseas Sales Dept, Asian RegionKFC bldg., 8F, 1-6-1 Yokoami, Sumida-ku, Tokyo 130-0015, JapanTEL +81-3-5819-8771 FAX +81-3-5819-8774Overseas Sales Dept, European & American RegionKFC bldg., 8F, 1-6-1 Yokoami, Sumida-ku, Tokyo 130-0015, JapanTEL +81-3-5819-8772 FAX +81-3-5819-8774

(Tools specifications subject to change without notice.)URL :

For Your SafetyaDon't handle inserts and chips without gloves. aPlease machine within the recommended application range and exchange expired tools with new ones in advance of breakage. aPlease use safety covers and wear safety glasses. aWhen using compounded cutting oils, please take fire precautions. aWhen attaching inserts or spare parts, please use only the correct wrench or driver. aWhen using rotating tools, please make a trial run to check run-out, vibration and abnormal sounds etc.

2014.10.E(5A)EXP-13-E033

Low cutting resistance, double sided insert face mill for general machining

WSX445

Coated CBN Grade for High Hardened Steel Turning

BC8110