Oerlikon Balzers

Schaumburg,  IL 
United States
http://www.oerlikon.com/balzers/us
  • Booth: 1323

Oerlikon Balzers is one of the world’s leading suppliers of surface technologies that significantly improve the performance and durability of precision components as well as tools for the metal and plastics processing industries. These coatings, developed under the brand names BALINIT and BALIQ, are extremely thin and exceptionally hard and significantly reduce friction and wear. Under the technology brand ePD, the company develops integrated services and solutions for the metallization of plastic parts yielding a chrome look. Oerlikon Balzers has a dynamically evolving network of currently 107 coating centers in 35 countries of Europe, North and South America and Asia. Together with Oerlikon Metco, Oerlikon Balzers is part of the Surface Solutions Segment of the Swiss Oerlikon Group (SIX: OERL).


 Press Releases

  • Schaumburg, IL, February 2017 -

    Developing tailored tool coatings plays an especially key role in increasing cutting speeds, raising productivity and lowering costs when working with demanding gear-cutting processes. The outstanding performance dimensions that can now be achieved in this respect are demonstrated in customer tests carried out by automobile manufacturers and suppliers on the BALINIT ALTENSA AlCrN coating introduced by Oerlikon Balzers in the United States in September 2016.

    Manufacturing durable, low-noise and highly efficient gears, such as for transmission applications, makes enormous demands on quality requirements and entails an accordingly high level of production effort. This is precisely the reason why industrial competition demands both the shortest possible production times and low production costs. A fundamental examination of the cost breakdown and opportunities for savings in the production process reveals where advantages can be gained:

    • On average, about 8 percent of the overall manufacturing costs are incurred by the cutting tools, including their coatings. Here, even favourable purchasing conditions allow only minimal savings to be realized.

    • The costs for cooling account for about 12 percent, depending on the cutting process chosen. Dry machining brings advantages here and is therefore often employed for gear cutting, but it is not suitable for every application.

    • The (machinery) setup costs amount to about 24 percent, and this can be lowered by increasing the service life of tools, thereby reducing the setup cycles.

    • At least another 26 percent of the manufacturing costs are due to other factors that cannot be influenced.

    • At about 30 percent, the actual machining costs make up the largest part. These costs can be reduced most effectively through higher cutting speeds.

      Modern wear-protection coatings are making an increasingly significant contribution to the savings opportunities pointed out here. They are generally a prerequisite for dry machining and are undergoing continuous refinement for this purpose. They increase the tool service life and thereby also reduce the setup costs. Above all, however, they demonstrate their strengths directly in cutting applications, enabling significantly higher cutting speeds. Since the introduction of the first TiN coatings for cutting tools in the 1980s, the coating specialist, Oerlikon Balzers, has been a major force in shaping this development. “Today, more than 60 percent of all hobs worldwide, which are used first and foremost in the automotive industry, are coated with our AlCrN coating, BALINIT ALCRONA PRO," says Dr. Wolfgang Kalss, Head of Marketing and Product Management for Cutting Tools at Oerlikon Balzers.

      For good reason: With coatings such as these, cutting speeds go up – and costs go down. An example calculation demonstrates this: If the speed of gear cutting can be increased from 200 to 300 m/min, the machining time (primary and secondary times) goes down from 0.56 to 0.42 minutes per gear. This means that machining costs go down by about 25 percent, based on the machine-hour rate. If the overall production costs for a gear are calculated, this represents a cost reduction of about 10 percent. Accordingly, investing in new substrate materials or coatings pays off.


 Products

  • BALINIT ALTENSA - PVD COATING
    PVD COATING BALINIT ALTENSA: AlCrN base coating produced by Oerlikon Balzers, a leader in Surface Solutions. This coating is the benchmark in coatings for gear cutting tools....

  • New horizons for high-speed gear cutting

    Schaumburg, IL, February 2017– Developing tailored tool coatings plays an especially key role in increasing cutting speeds, raising productivity and lowering costs when working with demanding gear-cutting processes. The outstanding performance dimensions that can now be achieved in this respect are demonstrated in customer tests carried out by automobile manufacturers and suppliers on the BALINIT ALTENSA AlCrN coating introduced by Oerlikon Balzers at in America in September, 2016.

    PVD COATING BALINIT ALTENSA: Thermal conductance and hot hardness are focus of improvement

    In order to better utilize this principle and make even higher cutting speeds possible for manufacturers, the properties of coatings need to be tailored to the respective applications with ever increasing efficiency. Oerlikon Balzers has made another great step in this direction with a further new development. The BALINIT ALTENSA is the newest product in the successful AlCrN family and it stands out especially through its wear resistance and hot hardness. In light of the market demand for ever higher machining speeds, the coating properties at high temperatures were specifically targeted for optimization. “Essentially, we further reduced the thermal conductance and improved the hot hardness of the coating by a good 20 percent,” explains Wolfgang Kalss, Head of Marketing and Product Management for Cutting Tools. This has led to even higher resistance to crater wear, which can occur particularly at high service temperatures and reduces the useful life of the tool.

    Moreover, the abrasive wear resistance was optimized by about 35 percent as was the oxidation resistance. This reduces the flank wear at moderate and high cutting speeds and it yields a longer tool service life, even with dry machining. The bottom line is that the numerous improvements in layer development enable considerable productivity gains with longer tool lifetimes, significant performance boosts at the highest cutting speeds for all substrates (PM HSS, MC90, carbide) as well as higher cutting speeds and feeds. Customer tests with various gear-cutting applications yielded corroborative results.

    The versatility of BALINIT ALTENSA is also proven in lubricated machining, in which initial results demonstrate a significant increase in service life.
    Tests by an automotive supplier demonstrated that productivity can also be clearly improved for carbide stick blades. At a cutting speed increase of 35 percent to vc=200 m/min, a 30 percent improvement in service life was also achieved at the same time. Another automotive supplier tested coated HSS shaper cutters (diameter of 130 mm) in lubricated machining and the tools lasted 140 percent longer.

     

    For further information please contact:

     

    Sergio Lopez

    Manager of Communications,

    Oerlikon Balzers, Americas

    T +52 442 209 68 33

    sergio.lopez@oerlikon.com

    www.oerlikon.com/balzers/us