The cutting performance of diamond and DLC-coated cutting tools
Introduction
Diamond and DLC films have many beneficial properties including high hardness, a low friction coefficient, high thermal conduction, and a low thermal expansion coefficient [1]. So the diamond and DLC film are considered as ideal cutting tool coatings for processing non-ferrous metals, non-metal materials, and composites, etc. At present the application of diamond and DLC films in cutting tools have been studied extensively [2], [3], [4], [5], [6], great progress has been achieved, lots of problems including adhesive strength have been solved to some extent [7]. But the cutting data of diamond or DLC coated cutting tools in published literature are very different. This means that the quality of diamond or DLC-coated cutting tools made by different units is different, and the cutting performance depends greatly on the quality of the coated tools, the cut materials and cutting parameter. Therefore, it is necessary to study further the cutting performance of diamond and DLC-coated cutting tools and obtain more cutting data. In this work, the cutting performance of diamond and DLC-coated inserts for cutting different materials are studied.
Section snippets
Deposition experimental
Diamond films were coated on cemented carbide substrates in DC plasma jet CVD equipment with 30 kW power and φ70 mm deposition area. DLC films were coated in vacuum cathode multi-arc deposition equipment with 8-arc resource. Then, using Philip XL30 FEG SEM, D/MAX-RC X-ray diffraction, Spex 1403 Raman spectrum, ESCA PHI 610/SAM AES, micro-indentation test, acoustical emission scratch test characterized the diamond and DLC films. The film deposition parameters are listed in Table 1, Table 2,
Characteristics of films
Fig. 1a shows the surface morphology of a diamond film deposited at related low methane (3% CH4), the diamond film is well faceted and dense. The methane content has great influence on the morphology of the diamond film, spherical crystal and porosity films were obtained with high CH4 content (more than 5% CH4). The cross-section of the diamond film shows that diamond grows in a columnar structure, as shown in Fig. 1b, the film thickness is less than 10 μm. It can be seen that the cemented
Conclusion
- 1.
The composition of cemented carbide substrate has an effect on adhesive strength of the diamond film, YG series (WC+Co) cemented carbides have better adhesive strength, so YG series cemented carbides are good tool substrates for diamond coating.
- 2.
The diamond-coated insert has a great advantage for cutting very abrasive materials, such as high Si content Al alloy. The wear life of the diamond-coated insert can be 55 times longer than the uncoated insert as the cutting Al–22% wt. Si alloy which is
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