Thinking Inside the Box

A thermal cycling process being applied to high-speed steel tools, solid carbide tools, carbide inserts, and PVD- and CVD-coated tools, has been shown to extend the life of tools by an minimum average of 2:1, while reducing tool changes due to longer tool life, less spindle downtime and higher productivity.

In addition, the treatment is cost effective. Low treatment cost extends the life of expensive tools and can reduce tooling costs by 50% or more; regrind time is reduced because tool performance is extended; and there is no affect on tool dimensions - tool size and cutting edge integrity are maintained.

BlueBox Technologies' thermal cycling technology creates a more uniform molecular structure, relieving stresses and allowing the treated material to dramatically improve its ability to dissipate heat and dampen vibration - two main contributors to tool fatigue and failure.

The cycling process accomplishes a complete molecular change with a revised energy path, creating higher wear resistance, higher heat resistance, higher tensile strength, and less brittleness. All desirable characteristics remain for any tooling that is cutting metal or parts that incur friction during their operation.

The process is cryogenically-based, using liquid nitrogen to cool parts to temperatures as low as -300°F. What BlueBox's patent is based on is the cycling of the part temperature once it has reach a "deep cold" state. This cycling will slowly adjust the temperature up and down via computer control with a stabilizing period at each different temperature level. Temperature and stabilizing periods vary with the part composition.

Parts or tools can be processed with or without traditional coatings. However, the BlueBox Process treats the total part and is not just a coating that must be re-applied when worn away. The same high performance characteristics present in a tool processed by BlueBox will be present after regrinds, further extending the life of the tool.

"This patented process does not affect part dimensions, nor does it decrease any part sharpness by rounding cutting edges," states Jim McGaffin, executive vice president of BlueBox Technologies. "It is a very cost-effective process that can reduce tooling and maintenance costs in every metalworking shop. We feel we are making a contribution towards keeping U.S. manufacturing competitive."

The process is targeted at cutting tools, but is also successfully applied to saw blades, punches and dies, shear blades, spindles, bearings and more.

"Where there is heat generated friction, the BlueBox thermal cycling process is a solution that should be looked at," McGaffin suggests.

More information can be found at BlueBox Technologies' website, www. blueboxtec.com. The site provides examples of typical applications of processed cutting tools on die steels, titanium, nickel alloys and stainless steels.