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Mitsubishi Materials awarded the 2007 CCMA Awards

Development of the new cermet grade, NX3035

1.Technical features
• Due to a dramatic improvement in thermal shock resistance and toughness that conventional cermets lack in, NX3035 achieves a highly stable cutting performance and therefore delivers increased tool life during finish cutting.

2.Novelty / Originality
• The conventional Co, Ni binder phase has low thermal conductivity, a special alloy binder with high thermally conductivity has been developed. As a result, NX3035 achieves the highest level of thermal conductivity, preventing thermal cracks due to thermal shock. Additionally, NX3035 uses hard substrate particles with high resistance to crack development. NX3035 also achieves high wear resistance as the surface offers higher hardness.

3.Contribution / Benefits for the Association
• NX3035 offers stable machining for difficult applications where high dimensional accuracy and surface finishes are required and enables further reduction of labour and tool costs with process automation and prolonged tool life. NX3035 with superior wear resistance to the conventional cermets and PVD cermets can be used in all application areas, this increases convenience for customers.

Development of the SPX deep shoulder milling end mill

1.Technical features
• For rough machining of slide faces for press moulds and mating faces of machine tool parts, the SPX with the unique wavy cutting edge geometry offers lower cutting resistance and reduced impact when the cutting edge engages the workpiece.

2.Novelty / Originality
• The smooth, wavy cutting edge of the inserts helps maintain fracture resistance and a differential pitch of the wavy cutting edges optimizes chip-breaking properties. Additionally, a convex surface of the rake face improves the chip separation.

3.Contribution / Benefits for the Association
• For rough machining of wall surfaces of large moulds, the SPX achieves high efficiency machining and this contributes to significant reduction in tool costs. The SPX demonstrates that a complicated geometry like a roughing cutting edge is also effective for indexable end mills, thus creating a new trend for tool design.

Development of the diamond coated drill for hard brittle materials

1.Technical features
• Increasing the adhesion properties of diamond to a carbide substrate and using a special geometry for brittle materials have achieved high accuracy drilling with long tool life when drilling fine ceramics and silica glasses.

2.Novelty / Originality
• The cutting edge geometry is designed to have a large cutting edge angle to improve fracture resistance. By having unevenness of polycrystalline diamond act as a fine quasi cutting edge and carry out machining with very low feeds, fine, powdered chips can be formed. As a result, it becomes possible to decrease the size of a drill’s chip evacuation flute and also increase fracture resistance. In addition, high adhesion properties of diamond coating can be maintained up to Ø0.05mm.

3.Contribution / Benefits for the Association
• Due to excellent fracture and wear resistance of the diamond coated drill, it is possible to reduce the number of tools and preparatory time for tool exchange, therefore contributing to a labour saving by unmanned operations and shortening of processes.