New materials and coating technologies have greatly improved the life and overall performance of cutting tools. A new surface finishing technology originally derived from the optical industry offers an alternative to improving the life of cemented carbide, cobalt high speed steel, high speed steel and PCBN tools. The new technology developed by Mikronite Technologies Inc. is a dry machining process that combines pressure with grinding media to grind and strain harden the entire surface of the tool (or part). This "grinding-like" process results in a hardened surface with better lubricity, smoothness, corrosion resistance and wear resistance. However, this surface can no longer be coated or plated.
The Mikronite process is ideal for machining tools with complex geometries such as hobs, drills, taps, reamers, etc. and cutting inserts. At the heart of the process system is a reversible centrifugal acceleration agitator. Place the tool (or part) in a container filled with non-corrosive grinding media and install the container on the blender. The agitator rotates the container clockwise, while at the same time it rotates counterclockwise along the circumferential path with the rotating container. This movement causes the workpiece in the container to withstand a force of more than 30 G, but the workpiece does not come into contact with the container wall; this movement also causes the grinding medium in the container to slide uniformly across the surface of the workpiece with evenly distributed pressure. This combination of pressure and oscillating causes the metal surface to break within a controlled depth without changing the size, shape or metallurgical properties of the workpiece. By this cold plastic deformation, a surface roughness of Ra < 1 μm can be produced, and at the same time, an optimum combination of the outer surface hardness and the internal toughness can be obtained. In addition, it provides better corrosion resistance for workpiece materials such as steel.
The Mikronite process can also be used in the automotive industry to increase the durability of interacting components by reducing the coefficient of friction between the mating surfaces. This technology has been applied to the surface treatment of power transmission boxes, valve trains and various other engine components. In addition, the process is used for surface finishing of medical and dental parts, aerospace components (such as engine turbine blades, shafting, etc.). Mikronite processes are suitable for machining workpiece materials including steel, aluminum alloys, titanium alloys, bearing steels, tool steels, hard alloys, silicon nitride, brass and bronze, and various ceramics and plastics.
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