Analyzing the performance of diamond-coated micro end mills

Torres, Christopher D.; Heaney, Patrick J.; Sumant, Anirudha V.; Hamilton, Matthew A.; Carpick, Robert W.; Pfefferkorn, Frank E.

doi:10.1016/j.ijmachtools.2009.02.001

Cited by 87 publications

(45 citation statements)

References 26 publications

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“…The main reason for this attention is that NCD films have a low surface roughness [1] while retaining bulk diamond mechanical properties and are used in a diverse array of applications from tribology [2] to machining [3], with advantages such as a low wear and friction coefficient [4] and a significant reduction in cutting forces [2] when used as coatings in applications such as machining [5], dental [6] and drilling [7]. NCD can be deposited using chemical vapor deposition techniques, mainly microwave plasma CVD [8,9] and hot filament chemical vapor deposition (HFCVD) [9][10][11].…”

Section: Introductionmentioning

confidence: 99%

Surface morphology and bond characterization of nanocrystalline diamonds grown on tungsten carbide via hot filament chemical vapor deposition

Hamzah

Yong

Yajid

2013

Journal of Crystal Growth

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Section: Introductionmentioning

confidence: 99%

Surface morphology and bond characterization of nanocrystalline diamonds grown on tungsten carbide via hot filament chemical vapor deposition

Hamzah

Yong

Yajid

2013

Journal of Crystal Growth

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“…chemistry vapour deposition (CVD) diamond or CBN coatings, are used in some applications to elongate tool life [20]. However, the thickness of the coatings would significantly increase the cutting edge radius by a few micrometres [21] and thus blunt the tool, although this might not be an issue for macro-scale cutting tools. In micromachining, however, the depth of cut is in the range of a few micrometres, and typical features of the microcomponent are in the range of tens to hundreds of micrometres; the well-known size effects will thus play a significant role and change the whole machining process physics.…”

Section: Introductionmentioning

confidence: 99%

“…In micromachining, however, the depth of cut is in the range of a few micrometres, and typical features of the microcomponent are in the range of tens to hundreds of micrometres; the well-known size effects will thus play a significant role and change the whole machining process physics. Therefore, increasing the cutting edge radius owing to coatings will negatively affect the micromachining performance [21], although they have a positive effect in terms of wear resistance and low cutting friction. More experimental results are expected to assess the coated microtool performance.…”

Section: Introductionmentioning

confidence: 99%

“…Most of the micromilling experiments reported in the literature were performed in miniature machine tools (MMTs) [22][23][24][25][26] or conventional machining centres with retrofitted high-speed spindles [11,15,21], which have limited stiffness or accuracy, and results may not be industrially applicable. Therefore, optimum cutting conditions from various micromilling tools, obtained directly from industrialprecision micromilling machines rather than MMTs and test beds, are desirable for micromachining, so as to bridge the gap.…”

Section: Introductionmentioning

confidence: 99%

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Experimental investigation on micromilling of oxygen-free, high-conductivity copper using tungsten carbide, chemistry vapour deposition, and single-crystal diamond micro tools

Huo

Cheng

2010

Proceedings of the Institution of Mechanical Engineers, Part B:

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Insufficient experimental data from various micro tools limit industrial application of the micromilling process. This paper presents an experimental comparative investigation into micromilling of oxygen-free, high-conductivity copper using tungsten carbide (WC), chemistry vapour deposition (CVD) diamond, and single-crystal diamond micromilling tools at a uniform 0.4 mm diameter. The experiments were carried out on an ultra-precision micromilling machine that features high dynamic accurate performance, so that the dynamic effect of the machine tool itself on the cutting process can be reduced to a minimum. Micromachined surface roughness and burr height were characterized using white light interferometry, a scanning electron microscope (SEM), and a precision surface profiler. The influence of variation of cutting parameters, including cutting speeds, feedrate, and axial depth of cut, on surface roughness and burr formation were analysed. The experimental results show that there exists an optimum feedrate at which best surface roughness can be achieved. Optical quality surface roughness can be achieved with CVD and natural diamond tools by carefully selecting machining conditions, and surface roughness, R a , of the order of 10 nm can also be obtained when using micromilling using WC tools on the precision micromilling machine.

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“…Torres et al [7] coated fine-grained diamond (FGD) and nano-crystalline diamond (NCD) films onto tungsten carbide micro end mills by a hot-filament chemical vapour deposition (HF-CVD) process. The performance of both coated tools in dry slot milling of aluminium shows a dramatic improvement in the tool integrity, lower wear rate, no observable adhesion and a significant reduction in the cutting forces compared to those of uncoated ones.…”

Section: Introductionmentioning

confidence: 99%

Micro milling performance assessment of diamond-like carbon coatings on a micro-end mill

Cheng

2013

Proceedings of the Institution of Mechanical Engineers, Part J:

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In micro milling, unpredictable tool life and premature tool failures are the major constraints for its industrial applications, and prolongation of the tool life so as to enhance the tooling performance presents great challenges. Appropriate coating techniques potentially offer a feasible and promising solution. In the research presented, diamond-like carbon (DLC) films are deposited on a Ø500µm diameter tungsten carbide (WC) micro end mill by the plasma enhanced chemical vapor deposition (PE-CVD) process. Coating characterization has been undertaken and the DLC coatings are found in good coverage on the tool except for a slight delaminating on the edge corners. Besides, the surface of the amorphous coatings is much smoother than that of WC. In addition, comprehensive cutting performance of the DLC coated tool in dry slot milling of Al 6061-T6 has been compared with those of uncoated tools in both dry and wet conditions. It is observed that the use of DLC coatings can reduce the cutting forces, lessen the tool wear, improve the surface roughness and minimize the microburr formation as compared to the corresponding performance of an uncoated tool in dry cutting. However, the performance improvement is still unreachable to those resulting from the cutting fluid influence.

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Analyzing the performance of diamond-coated micro end mills

Cited by 87 publications

References 26 publications

Surface morphology and bond characterization of nanocrystalline diamonds grown on tungsten carbide via hot filament chemical vapor deposition

Surface morphology and bond characterization of nanocrystalline diamonds grown on tungsten carbide via hot filament chemical vapor deposition

Experimental investigation on micromilling of oxygen-free, high-conductivity copper using tungsten carbide, chemistry vapour deposition, and single-crystal diamond micro tools

Micro milling performance assessment of diamond-like carbon coatings on a micro-end mill

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