ProWerWolf – Tool and process configuration to improve machinability and increase process reliability in the milling of WC-Co cemented carbides

Tool wear on stamping and forming tools has a significant influence on the costs and quality of products in mass production. Current studies show that the use of carbide as a tool material can reduce wear and consequently increase tool life. For this reason, the use of carbide for punching dies, punches and press sleeves has become more and more established. Compared to conventional machining by EDM, grinding and polishing, the manufacture of carbide tool inserts by milling offers great potential to increase economic efficiency and geometrical freedom. However, the configuration of this milling process is challenging due to a lack of knowledge about the influence of the material, the tool, the coating and the process conditions on the machinability.

In the ProWerWolf project, experimental investigations are performed to develop a planning model that supports companies in the optimized tool and process configuration for milling tungsten carbide using CVD-diamond coated solid carbide tools. To achieve this goal, fundamental considerations are first carried out by performing orthogonal cutting tests using different test materials, tool coatings as well as tool macro- and tool micro-geometries. The gained knowledge is used to configure roughing and finishing milling tests, in which the influences of path planning as well as tool cooling on tool life is considered. Finally, the elaborated planning model for milling carbide is compared to conventional manufacturing methods (EDM, grinding and polishing) in a benchmark in order to provide companies with a decision basis for the operational implementation of tungsten carbide milling