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 average minimum 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 because tool size and cutting edge integrity are maintained.

The process is cryogenically-based, using liquid nitrogen to cool parts to temperatures as low as -300°. BlueBox's patent is based on 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.

The BlueBox process is said to provide the following benefits to users:

• Longer tool – less tool costs
• Improved performance for solid tools or inserts
• Reduced tool changes – more spindle up time
• Higher speeds and feeds – increased production
• Cost effective treatment costs – reduced tooling budgets

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 tool life.

"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," states Jim McGaffin, executive vice president of BlueBox Technologies.

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

In order for users to become more informed on the process, BlueBox Technologies has launched a website explaining the advantages of the BlueBox thermal cycling process. The website – blueboxtec.com – provides examples of typical applications of processed cutting tools on die steels, titanium, nickel alloys and stainless steels.