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Graphic element Research > Growth > Research projects > Previous projects > Industrial Processes > New software for designing tools with structural gradients for milling applications
Graphic element New software for designing tools with structural gradients for milling applications
     
 
New computational aids allow design and testing of different combinations of coatings and graded substrates to optimise load carrying and crack resistance in milling tools.
 

In machining operations, tools are exposed to severe conditions of mechanical loading, wear and temperature, and many operations, such as milling, involve the intermittent engagement of the tools. Under these conditions, cracks can easily propagate, causing chipping and ultimately tool failure.

This project's objective was to develop computational design aids for new generation milling tools based on coated hard metals with gradient structures. These computational aids allow a tool designer to test different combinations of coatings and substrates to optimise load carrying and crack resistance for the particular application. The transition from non-coated hard metal milling grades to optimised coated grades with gradient structures will effectively increase tool life, possibly by 50 %, with consequent benefits in machining efficiency and costs.

The new tool set will allow tool designers to move away from trial and error and will greatly improve machining efficiency, say partners, and with the world-wide cost of milling estimated at 50,000 MECU, 25 % of which is incurred in Europe, only a small percentage improvement would have a large economic impact.

Cordis RCN: 22821
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