Fraunhofer Institute for Material and Beam Technology IWS
Fraunhofer Institute for Material and Beam Technology IWS

Edge Sharpening

Coating Technology for the Targeted Setting of Edge Radii

Cutting edge of a cutter knife coated using the new edge coating technology. Edge rounding due to the grown-on coating was largely avoided.
© Fraunhofer IWS
Cutting edge of a cutter knife coated using the new edge coating technology. Edge rounding due to the grown-on coating was largely avoided.
Cutting edge of a cutter knife coated with a standard process. Despite the same initial geometries and the same coating thicknesses (cf. picture above), the edge radius is significantly increased by the coating, and the knife is blunt.
© Fraunhofer IWS
Cutting edge of a cutter knife coated with a standard process. Despite the same initial geometries and the same coating thicknesses (cf. picture above), the edge radius is significantly increased by the coating, and the knife is blunt.

Project Aims

  • Development of a coating process for the targeted, variable adjustment of the edge sharpness (edge radius) on a workpiece (e.g. a tool) exclusively through the growing coating,
  • Further development of the model concepts for the layer growth at edges,
  • Evaluation of the durability of the manufactured edges in a model test and their qualification for application-specific mechanical stress,
  • Creation and testing of demonstrators for various target applications and estimation of future, industrial feasibility
     

Solution

Preliminary work has shown that targeted process control during coating (process gas pressure, evaporator current, electrical substrate bias voltage, magnetic fields) in conjunction with an adapted coating system can produce edge radii that are smaller than in the initial state. In the project, the dependencies and model concepts found in this process are to be used and further developed in order to achieve a targeted adjustment of the edge radius.
 

Desired Results

The result of the project is a coating process that allows the edge radius of coated substrates to be adjusted exclusively by the growing layer. A further development of models for layer growth at edges is aimed at. At the end of the project, coated and tested demonstrator tools as well as a well-founded assessment of the industrial feasibility will be available.

Benefits for Small and Medium-Sized Enterprises

The new technology is expected to be applied to a wide variety of tools with defined edges. Tools will thus become more efficient, durable and reliable. Interested companies are primarily tool and component manufacturers, coating service providers and users of the tools. Particularly in the area of special tools and coating, SMEs are primarily active. For these companies in particular, there are opportunities to expand current market positions and open up new markets.