Cutting performance of nano-crystalline diamond (NCD) coating in micro-milling of Ti6Al4V alloy

Aslantaş, Kubilay; Hopa, H.E.; Perçin, Mustafa; Ucun, İrfan; Çıçek, Adem

doi:10.1016/j.precisioneng.2016.01.009

Cited by 94 publications

(32 citation statements)

References 24 publications

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“…Nanocrystalline diamond (NCD) films have shown promise as a hard coating material for enhancing the performance of cutting tools and prolonging tool lifetime. NCD films introduce the highest known hardness, a smooth surface, and a low friction coefficient, resulting in fine diamond grains, less than 100 nm in size [1][2][3]. Ultrananocrystalline diamond (UNCD) films, a kind of NCD film comprising grains less than 10 nm [4,5], are a promising candidate as a hard coating application on cutting tools [6].…”

Section: Introductionmentioning

confidence: 99%

Effects of Air Exposure on Hard and Soft X-ray Photoemission Spectra of Ultrananocrystalline Diamond/Amorphous Carbon Composite Films

et al. 2018

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Hard X-ray photoemission spectroscopy (HAXPES) was employed for the structural evaluation of ultrananocrystalline diamond/amorphous carbon (UNCD/a-C) composite films deposited on cemented carbide substrates, at substrate temperatures up to 550 °C by coaxial arc plasma deposition. The results were compared with those of soft X-ray photoemission spectroscopy (SXPES). Since nanocrystalline diamond grains are easily destroyed by argon ion bombardment, the structural evaluation of UNCD/a-C films, without the argon ion bombardment, is preferable for precise evaluation. For samples that were preserved in a vacuum box after film preparation, the sp3 fraction estimated from HAXPES is in good agreement with that of SXPES. The substrate temperature dependencies also exhibited good correspondence with that of hardness and Young’s modulus of the films. On the other hand, the sp3 fraction estimated from SXPES for samples that were not preserved in the vacuum box had an apparent deviation from those of HAXPES. Since it is possible for HAXPES to precisely estimate the sp3 fraction without the ion bombardment treatment, HAXPES is a feasible method for UNCD/a-C films, comprising nanocrystalline diamond grains.

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Section: Introductionmentioning

confidence: 99%

Effects of Air Exposure on Hard and Soft X-ray Photoemission Spectra of Ultrananocrystalline Diamond/Amorphous Carbon Composite Films

et al. 2018

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“…They showed that when BUE is not present, theoretical surface roughness models yield acceptable predictions. Ucun et al [13] and Aslantas et al [14] both studied the finish micro milling operation and observed that coated tools minimize BUE and help improve surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Built-up edge effects on process outputs of titanium alloy micro milling

Oliaei

2017

Precision Engineering

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Built-up edge (BUE) is generally known to cause surface finish problems in the micro milling process. The loose particles from the BUE may be deposited on the machined surface, causing surface roughness to increase. On the other hand, a stable BUE formation may protect the tool from rapid tool wear, which hinders the productivity of the micro milling process. Despite its common presence in practice, the influence of BUE on the process outputs of micro milling has not been studied in detail. This paper investigates the relationship between BUE formation and process outputs in micro milling of titanium alloy Ti6Al4V using an experimental approach. Micro end mills used in this study are fabricated to have a single straight edge using wire electrical discharge machining. An initial experimental effort was conducted to study the relationship between micro cutting tool geometry, surface roughness, and micro milling process forces and hence conditions to form stable BUE on the tool tip have been identified. The influence of micro milling process conditions on BUE size, and their combined effect on forces, surface roughness, and burr formation is investigated. Long-term micro milling experiment was performed to observe the protective effect of BUE on tool life. The results show that tailored micro cutting tools having stable BUE can be designed to machine titanium alloys with long tool life with acceptable surface quality.

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“…Particularly, the 75nm surface roughness Ra, which is better than most previously reported value on titanium alloy Ti-6Al-4V, was achieved in Test no.1 [22]. Aslantas et al [23] reported an investigation on micro-milling titanium alloy Ti-6Al-4V by 0.5 mm nano-crystalline diamond coated tools and the surface finish values acquired were within the scope of 0.2 μm and 1μm. Furthermore, the evolution rule of surface precision with tool geometrical transformation were plotted in Fig.…”

Section: Surface Finish Of Workpiecementioning

confidence: 75%

Experimental and multiscale numerical investigation of wear mechanism and cutting performance of polycrystalline diamond tools in micro-end milling of titanium alloy Ti-6Al-4V

Bai

Tong

2018

International Journal of Refractory Metals and Hard Materials

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The present study reports on experiments and numerical simulations carried out to determine the wear and cutting performance of different polycrystalline diamond (PCD) tools in micro-end milling titanium alloy. The influence of tool geometrical parameters on wear resistance and machined surface precision was discussed. Furthermore, subsurface microstructure alteration was employed as an important index for evaluating the cutting performance of PCD tools. A dislocation dynamics-based multiscale framework, which is capable of promulgating the potential mechanism of above alteration, was adopted to quantitatively predict the evolution behavior of subsurface damages layer during micro-cutting process. The results demonstrated that the tool nose, flank and rake wear were of major wear forms and inappropriate tool structural changes can further accelerate tool failure. A PCD tool with rake angle of 5°, clearance angle of 15°, tool cutting edge radius of 20 μm and PCD granularity of 10 μm has highest cutting performance among the tested tools. Using this cutting tool, a surface roughness of Ra = 75nm better than most previously reported value on titanium alloy Ti-6Al-4V was achieved. A mass of subsurface damages consisted of discrete dislocation configuration, parallel glide lines and persistent slip bands were found after machining. Particularly, small tool cutting edge radius, large rake as well as clearance angle contributed to reducing defects quantity and decreasing the thickness of subsurface damages layer.

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Cutting performance of nano-crystalline diamond (NCD) coating in micro-milling of Ti6Al4V alloy

Cited by 94 publications

References 24 publications

Effects of Air Exposure on Hard and Soft X-ray Photoemission Spectra of Ultrananocrystalline Diamond/Amorphous Carbon Composite Films

Effects of Air Exposure on Hard and Soft X-ray Photoemission Spectra of Ultrananocrystalline Diamond/Amorphous Carbon Composite Films

Built-up edge effects on process outputs of titanium alloy micro milling

Experimental and multiscale numerical investigation of wear mechanism and cutting performance of polycrystalline diamond tools in micro-end milling of titanium alloy Ti-6Al-4V

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