A coating comprising a bottom layer comprising a hard physical vapor deposition (PVD) coating applied to the end mill. The bottom layer has an edge-prep and polished top surface with reoriented cutting forces. The coating includes a top layer comprising a friction reducing coating applied to the top surface of the bottom layer to prevent or minimize titanium or titanium alloy adhesion to the end mill during milling operations of a metal object comprising the titanium or titanium alloy. The coating has a chemical composition which has inertness toward titanium or titanium alloy. A cutter tool and method are also provided.

In one aspect, coatings are described herein employing composite architectures providing high aluminum content and high hardness for various cutting applications. For example, a coated cutting tool comprises a substrate and a coating comprising a refractory layer deposited by physical vapor deposition adhered to the substrate, the refractory layer comprising a plurality of sublayer groups, a sublayer group comprising a titanium aluminum nitride sublayer and an adjacent composite sublayer comprising alternating nanolayers of titanium silicon nitride and titanium aluminum nitride.

The present invention is an end-mill (A) comprising a shank (B) and a cutting portion (C) along its longitudinal axis (4), and formed by combining ceramic and metal based materials via brazing method, comprising: a cutting diameter (1) varying between 2 to 20 mm, at least one web thickness (18) 0 found at a blade (26) part, at least one helix angle (10) having a cutting edge (13) thereon, a core diameter (16) that is at least 0.7 times the cutting diameter (1), at least one corner radius (5) found at the tip part of the blades (26) between the flutes (9) and axial and radial rake angles (17) at which cutting operation is made. TiAlN coating is applied over ceramic-metal based 5 end-mill (A) by PVD method in order to extend the service life of the end-mill, increase abrasion resistance, and minimize the welding (sticking) problem of chips on the cutting tools.

The invention is a monolithic end-mill cutter set (A) that can be made of ceramic and/or other materials having high strength and toughness and comprising a shank part (B) along a longitudinal axis (4) and a cutter part (C), comprising: a cutting diameter (1) varying between 2 to 20 mm, at least one web thickness (18) found at a blade (26) part, at least one helix angle (10) having a cutting edge (13) thereon, a core diameter (16) that is at least 0.7 times the cutting diameter (1), at least one corner radius (5) found at the tip part of the blades (26) between the flutes (9) and axial and positive radial rake angles (17) at which cutting operation is made. It has a wide helix angle interval and a positive rake angle. Titanium Aluminium Nitride TiAlN coating can be made on the monolithic end-mill cutter set (A) via PVD coating method in order to extend the service life of the end-mill cutter set (A), increase the abrasion resistance, and minimize the problem of sticking of rake on the cutter set (joining).

A solid carbide milling cutter has a substrate of hard metal and a multi-layer coating deposited at least to surface regions that contact a workpiece during a milling operation. The multi-layer coating includes a single-layer or a multi-layer functional layer deposited directly on the substrate surface and a single-layer or a multi-layer covering layer deposited on the functional layer. The functional layer has one or more layers of Ti.sub.xAl.sub.1-xN with 0.3x0.55. The covering layer has one or more layers of ZrN. The functional layer and the covering layer are deposited by HIPIMS, wherein during the deposition of the functional layer power pulses are applied to each sputtering target consisting of material to be deposited, which power pulses transfer an amount of energy to each sputtering target that exceeds a maximum power density in the pulse of 500 W/cm.sup.2.

Even if chips enter a gap between a flank face and a surface to be worked, the defect of the flank face or a cutting edge is suppressed by the control of the flow of the chips. A plurality of cutting edges, which are undulated in wave forms in a direction of an axis, are formed on an outer periphery of a front end portion of an end mill body rotating about the axis so that phases of the wave forms are displaced from each other in a path of rotation about the axis; flank faces of the cutting edges are covered with a coating film; and rough surface regions and smooth surface regions are alternately formed on the surface of at least portions of the coating film, which are close to the cutting edges, in the direction of the axis.

One aspect of the disclosure relates to a cutting tool for forming a final opening in a stack that includes at least two layers and a pilot opening having a pilot-opening dimension and extending through at least one of the at least two layers. The cutting tool includes a shank. The cutting tool also includes a first portion including at least one of a first coating or the first coating and a second coating, wherein the first coating at least partially covers the first portion. The cutting tool also includes a second portion between the shank and the first portion, wherein the second portion includes the second coating, and wherein the second coating at least partially covers the second portion.

A tool for machining in which defective adhesion of a coating film at an interface of a layer containing titanium and an alumina layer is prevented. A method for producing a tool for machining is provided in which a coating film of a plurality of layers is formed on a surface of a base material by physical vapor deposition (PVD), the method including: a first layer formation step of forming a first layer containing a nitride or carbide of titanium on the surface of the base material; a first barrier layer formation step of forming a barrier layer that covers a surface of the first layer; and a second layer formation step of forming a second layer containing aluminum oxide on a surface of the barrier layer.

Provided are: a hard lubricating coating film which is hard and has wear resistance; and a hard lubricating coating film-covered tool. A hard coating film (10), which is hard and has wear resistance, and an end mill (12) can be obtained by alternately forming two or more (CraMobWcVdBe)1-x-yCxNy layers A (22) and two or more (CraMobWcVdBe)1-x-y-zCxNyOz layers B (24) by controlling the composition ratios of Cr, Mo, W, V and B and various reaction gases during the film formation, or alternatively by controlling only the various reaction gases during the film formation. In this connection, the atomic ratios a-e, y and (x+y) of the layers A (22) are within predetermined ranges; the atomic ratios a-e, x, y, z and (x+y+z) of the layers B (24) are within predetermined ranges; the film thickness (D1) of the layers A (22) is within the range from 2 nm to 1,000 nm (inclusive); the film thickness (D2) of the layers B (24) is within the range from 2 nm to 500 nm (inclusive); and the total film thickness (D) is within the range from 0.1 m to 10.0 m (inclusive).

In order to achieve a long service life for a machining tool, in particular for a solid carbide drill, it is provided with a special wear protection coating. In a first method step, in order to form this coating, a first layer made of a first material is applied in the region of a cutting edge and in the adjoining surface regions, and specifically, a flank face and a rake face. In a second step, the applied first material of the first layer is selectively removed at least partially, and preferably completely, only in the region of the cutting edge. Finally, in a third method step, a second layer made of a second wear-resistant material is applied both to the cutting edge and to the face regions. In this way, a coating having a high overall thickness in the face regions is made possible, without the risk of cracking.