Diamond coatings for micro end mills: Enabling the dry machining of aluminum at the micro-scale

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

doi:10.1016/j.diamond.2007.12.009

Cited by 103 publications

(49 citation statements)

References 18 publications

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“…This includes coatings for high-performance tools 4 , hard-disks 5,6 , microelectromechanical systems (MEMS) 7 , automotive and aerospace components 8,9 , and atomic force microscope probes 10 .…”

Section: Introductionmentioning

confidence: 99%

Quantitative Evaluation of the Carbon Hybridization State by Near Edge X-ray Absorption Fine Structure Spectroscopy

2016

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The characterization of the local bonding configuration of carbon in carbon-based materials is of paramount importance since the properties of such materials strongly depend on the distribution of carbon hybridization states, the local ordering, and the degree of hydrogenation. Carbon 1s near edge X-ray absorption fine structure (NEXAFS) spectroscopy is one of the most powerful techniques for gaining insights into the bonding configuration of near-surface carbon atoms. The common methodology for quantitatively evaluating the carbon hybridization state using C1s NEXAFS measurements, which is based on the analysis of the sample of interest and of a highly ordered pyrolytic graphite (HOPG) reference sample, was reviewed and critically assessed, noting that inconsistencies are found in the literature in applying this method. A theoretical rationale for the specific experimental conditions to be used for the acquisition of HOPG reference spectra is presented together with the potential sources of uncertainty and errors in the correctly computed fraction of sp 2 -bonded carbon. This provides a specific method for analyzing the distribution of carbon hybridization state using NEXAFS spectroscopy. As an illustrative example, a hydrogenated amorphous carbon film was analyzed using this method, and showed good agreement with X-ray photoelectron spectroscopy (which is surface sensitive).Furthermore, the results were consistent with analysis from Raman spectroscopy (which is not surface sensitive), indicating the absence of a structurally different near-surface region in this particular thin film material. The present work can assist surface scientists in the analysis of NEXAFS spectra for the accurate characterization of the structure of carbon-based materials.3

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Section: Introductionmentioning

confidence: 99%

Quantitative Evaluation of the Carbon Hybridization State by Near Edge X-ray Absorption Fine Structure Spectroscopy

2016

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“…Although carbide tools with diamond coating layers have recently come on to the market [6], they are not widely employed and are still under research. Diamond coatings for micro mills are advantageous and promising because they are capable of reducing flute clogging by eliminating adhesion of the work material to the tool surface, reducing tool wear due to high hardness and reducing cutting forces due to low friction coefficients against many materials [3].…”

Section: Introductionmentioning

confidence: 99%

“…Appropriate coatings can be used on micro milling tools so as to extend their cost effectiveness and efficiency of the production process in terms of improved surface quality, increased tool life span, reduction in machine downtime and reduction in risk of damage as a result of tool wear or breakages [2]. The tool coating also enables the possibility of dry machining due to a lower friction coefficient between the coating and work materials [3].…”

Section: Introductionmentioning

confidence: 99%

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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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“…However, there are a number of applications where traditional fluid lubrication strategies are either precluded or undesirable. 3,4 Materials tribology, and in particular solid lubrication, is an area of research that aims to control friction and wear through both the appropriate selection of known materials and the development of new materials and surface treatments.…”

Section: Introductionmentioning

confidence: 99%

Accessing Inaccessible Interfaces: In Situ Approaches to Materials Tribology

Sawyer¹,

Wahl²

2008

MRS Bull.

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The field of materials tribology has entered a phase of instrumentation and measurement that involves accessing and following the detailed chemical, structural, and physical interactions that govern friction and wear. Fundamental tribological research involves the development of new experimental methods capable of monitoring phenomena that occur within the life of a sliding contact. Measuring friction phenomena while the process is ongoing is a major improvement over earlier techniques that required the surfaces to be separated and analyzed, thereby interrupting the frictioncausing event and modifying surface conditions. In the past, MRS Bulletin has highlighted how in situ approaches can greatly enhance our understanding of materials structure, processing, and performance. This issue highlights in situ approaches as applied to materials tribology, namely, the study of contacting surfaces and interfaces in relative motion.

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Diamond coatings for micro end mills: Enabling the dry machining of aluminum at the micro-scale

Cited by 103 publications

References 18 publications

Quantitative Evaluation of the Carbon Hybridization State by Near Edge X-ray Absorption Fine Structure Spectroscopy

Quantitative Evaluation of the Carbon Hybridization State by Near Edge X-ray Absorption Fine Structure Spectroscopy

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

Accessing Inaccessible Interfaces: In Situ Approaches to Materials Tribology

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