Since the first generation of coated inserts debuted in the 1960s, coating technology has revolutionized the cutting industry. Today, coated tools account for over 50% of all cutting tool production and continue to expand, making them a crucial area of research and innovation for major tool manufacturers. So, with such a wide array of coated tool products, how can we select the best and truly improve production efficiency?
Today, let's take a look at Kennametal's new-generation composite nano-coating technology, KENGold™, and explore the qualities that make a superior coated tool a priority. (Click here to lock in three surprise gifts at the end of this article.)
Golden Appearance: Unique and Practical
The defining feature of KENGold™ coated tools is their distinctive golden color. This isn't just a dazzling "coating," but a visual indicator of wear. The golden surface makes wear evident at a glance, making it easy to determine when to change tools.
Beneath this golden exterior lies a truly advanced composite coating technology. Since 1938, Kennametal has been committed to innovation and quality, and each of its pioneering materials represents a technological milestone. This time, Kennametal once again defies tradition and pushes the boundaries of tool performance.
Compound coating, hardcore performance
Comprehensively improved wear resistance, heat resistance, and fracture resistance
Take the KCP25C insert, a representative grade from KENGold™ technology, as an example. Test cutting was conducted under the same cutting conditions as the previous-generation grade insert.
After 5 minutes of test cutting:
The previous-generation grade insert showed noticeable wear and slight chipping. The KCP25C grade insert remained virtually undamaged.
After 10 minutes of test cutting:
The previous-generation grade insert showed chipping on the flank surface. The KCP25C grade insert showed minimal wear.
Laboratory data shows that KCP25C offers 160% greater wear resistance, 190% greater heat resistance, and 60% greater fracture resistance compared to the previous-generation grade.
This comprehensive performance improvement comes from comprehensive upgrades from the substrate to the coating and process:
• The gold TiN coating is wear-resistant and easily detects wear;
• The Al2O3 nanostructured coating offers excellent wear resistance and thermal insulation;
• The intelligent transition coating achieves a transition from tough to wear-resistant coating;
• The highly cubic, uniform structure of the reinforced MT-TiCN coating resists chipping.
Each layer performs its own function and blends seamlessly, ultimately achieving a perfect balance of hardness and toughness.
CVD and PVD combine to create complementary advantages.
PVD uses a physical vapor phase process to form thin, smooth coatings; CVD uses a chemical reaction to create thick, wear-resistant coatings. KENGold™ technology develops both CVD and PVD grades, adapting to a wider range of processing needs and leveraging their complementary advantages.
KCP25C (CVD): An All-Round Steel Machining Tool
• Improved MT-TiCN/alumina coating for enhanced thermal insulation;
• Effectively resists crater and flank wear for a longer and more stable tool life;
• Easily identifies used and unused cutting edges, reducing waste;
• Suitable for machining a wide range of steels (carbon steel, alloy steel, etc.).
KCU10B/KCU25B (PVD): A Versatile Tool
• Nanocomposite coating (TiSiN/AlTiSiN/AlTiN) for superior resistance to plastic deformation and edge wear;
• Also offers the advantage of gold-plated wear visualization;
• KCU10B offers increased wear resistance, while KCU25B offers increased toughness;
• Ideal for machining steel, stainless steel, cast iron, and high-temperature alloys;
• A comprehensive range of ISO-standard inserts available.
Click here to win a free trial
"True gold" is not afraid of fire, and our experience speaks for itself.
Life increased by up to 300%
Material: Stainless steel M1;
Application: OD external grooving;
Customer requirement: Improved cost-effectiveness;
Tool: A4G0305M03U04GMP KCU10B;
Cutting speed (vc): 130 m/min;
Feed (fz): 0.06 mm/z;
Depth of cut (ap): 3 mm;
Length: 5 mm x 2 processes.
Result: KCU10B grade increases tool life by 300%. The customer is very satisfied with the efficiency and life of the insert!
Improved Efficiency and Tool Life
Processing Requirements: P2 steel, black surface, end face roughing;
Customer Needs: Improved efficiency and tool life;
Processing Tool: CNMG190616RN KCP25C;
Cutting Speed (vc): 138 m/min;
Deepth of Cut (ap): 10 mm;
Feed per Tooth (f): 0.8 mm/r.
Result: After using the KCP25C, tool life increased by 200% and efficiency by 100%. The customer was very satisfied!
A Reliable Choice
ITD Engineering increased the number of parts processed per insert from 200 to 300, doubling tool life and achieving significant cost savings by adopting the KCP25C.
Using CNMG inserts with the KCP25C grade, Horn Equipment significantly reduced cycle time per workpiece from 4 minutes to just 15 seconds, achieving impressive efficiency.
