The quality of machined milled, turned and grinded parts depends on the cutting tools used in the manufacturing process. This is why pieces like milling cutters require surface finishing processes to enhance their performance and longevity.
Smoothing the surface, decoating, deburring, controlled rounding, and corrosion protection extend the life of cutting tools, ensuring reliable and repeatable quality in the final parts.
Between 12 to 15% of manufacturing costs and 30 to 50% of manufacturing time in the toolmaking industry are allocated to surface finishing.
Since current automated polishing techniques are rarely applicable to tools with freeform surfaces and function-critical edges, processes like smoothing, rounding or, radiusing, and deburring are still largely done manually or through complex multi-step methods, which can be error-prone and resource-intensive.
Benefits of DLyte surface finishing processes
Dry electropolishing technology is a novel electrochemical process that improves the result of current finishing technologies. It overcomes the barriers of liquid electropolishing and abrasive polishing using solid particles to remove material by ion exchange.
- As it is a non-abrasive treatment it does round off the edges in a controlled way.
- Performs automated effective surface finishing for cutting tools.
- It Improves dramatically the performance and lifespan of the tools.
- It is also able to improves the surfaces without changing the geometries.
- It reduces chipping on cutting tools, wear.
Some of the most important applications of our technology for cutting tools are:
- Boring bars
- Lathe cutting tools
- Milling cutters
- Saw blades
- Shaper tools
- Shearing machine blades
- Endmills, drills and cutting inserts
DLyte Technology and Rösler Experience, a perfect match for your success!
Cemented carbides
DLyte technology offers a plethora of advantages when it comes to the surface treatment of cemented carbides. By maintaining superficial chemistry unaltered, it ensures that the original properties of the material are preserved. Additionally, DryLyte technology prevents any leaching effects on the metallic binder, which contributes to the overall stability and durability of the treated surface. The process achieves an impressive roughness between constitutive phases of below 9 nm, resulting in a smooth and consistent surface finish.
The controlled rounding effects further enhance the final surface quality, ensuring uniformity and reduced wear. Moreover, the mechanical integrity of the treated material remains constant, demonstrating the non-invasive nature of the process. Finally, DryLyte technology boasts short polishing times, increasing productivity and efficiency in industrial applications.
Some applications
Carbide insert die polishing
Material: Tungsten carbide
Manufacturing: Sintering
Pre-processing: EDM
Application: Precision finish
Achieved Ra: 0.01 μm
Processing time: 94 minutes (1 part)
DLyte equipment: DLyte 100PRO Carbide
Common materials
01.
Carbon Steel
An alloy made of iron and carbon. Its properties are mainly defined by the amount of carbon it has, determining the hardness, ductility, and tensile strength of the steel. The strength and durability of carbon steel make it suitable for many industries, as it withstands higher levels of wear and tear.
02.
Cemented carbide (WC-Co)
Hard, wear-resistant material consisting of small hard carbide particles suspended in a metallic matrix. It is commonly used in the tooling industry due to its high strength and wear and heat resistance, which make it well-suited for use in a variety of cutting, drilling, and milling applications.
03.
High speed tool steel (HSS)
It is a steel alloy that contains tungsten and vanadium, which increases the strength and durability of metal pieces. It was designed to be used at high-cutting speeds, and is known for its ability to maintain a sharp edge and resist wear and deformation at high temperatures. An extremely common material in the tooling industry.
Technical aspects
Preservation of geometry without rounding edges
Improved passivation and corrosion resistance
Assured reliability and repeatability
Improved quality of forming, stamping and cutting tools
Smoothing drill flutes increases work speed and lifespan
Improved chip removal increases tool productivity
Reduction of wear and increased contact area
Reduced friction and defined edge rounding for longer tool life
Avoids leaching of cobalt in tungsten carbides
Reduced force and lubricant required for deformation
Economic and environmental aspects
Short processing time in a compact design
No devices to manage sewage and sludge
High profitability and short payback time
Environmentally friendly
Protects workers' health
DLyte success cases in the cutting tools industry
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