Tool coating is a decisive factor for process reliability in thread production. With HiPIMS technology, CemeCon has developed a new coating material specifically for HSS taps and formers. TapCon®Gold is precisely tailored to the requirements of the machining task and enables a leap in performance in thread production.
Internal thread production, whether through or blind hole, is one of the most demanding machining tasks, as threading is one of the last, if not the last, work steps. If process errors occur here, reworking is often time-consuming and cost-intensive or the almost finished component is even rejected.
Threading tools must therefore not only have a long service life, but also achieve consistent thread quality and tolerance throughout their service life. This places specific demands not least on the coating. For many years, traditional TiN and TiCN coatings have been the reference on threading tools. With the development of the gold-colored HiPIMS coating material TapCon®Gold specifically for HSS taps and formers, there has been a leap in performance for the first time.
Torque is a decisive factor in thread production. The lower it is, the greater not only the safety reserve until the tool reaches its limits, but generally the better the quality of the cut or formed thread. When machining tempered steel (vc = 42 m/min) with an HSS tap (M8 × 1.25 mm), for example, the TapCon®Gold coating ensures a torque of 2.73 Nm. With a TiN coating, on the other hand, significantly higher values of 3.37 Nm are achieved. This is due to the fact that coating materials produced with HIPIMS such as TapCon®Gold are extremely smooth, very dense and adhere well, even on complex tool geometries. This is particularly important for low torques when tapping and forming threads. Further advantages of the new coating are that material adhesion to the taps is avoided, excellent chip removal can be achieved and the running-in behavior is also outstanding thanks to the very low-friction surface. The high toughness of the HiPIMS coating material also provides optimum protection for the cutting edges during tapping.
Furthermore, the specific composition of the coating material leads to an impressive cutting performance. An example: When machining C45, taps with a conventional TiN coating cut an average of 432 threads (±10 percent), with TapCon®Gold the average was 690 threads (± 10 percent). That is an increase of around 60 percent! The quality of the cut thread is excellent right down to the last hole. Various tool manufacturers have already successfully tested TapCon®Gold and started series production.
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