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QQ: 763077177 (非诚勿扰) Coating thickness effects on diamond coated cutting tools F. Qin, Y.K. Chou,D. Nolen and R.G. Thompson

Available online 12 June 2009. Abstract ：

Chemical vapor deposition (CVD)-grown diamond films have found applications as a hard coating for cutting tools. Even though the use of conventional diamond coatings seems to be accepted in the cutting tool industry, selections of proper coating thickness for different machining operations have not been often studied. Coating thickness affects the characteristics of diamond coated cutting tools in different perspectives that may mutually impact the tool performance in machining in a complex way.

In this study, coating thickness effects on the deposition residual stresses, particularly around a cutting edge, and on coating failure modes were numerically investigated. On the other hand, coating thickness effects on tool surface smoothness and cutting edge radii were experimentally investigated. In addition, machining Al matrix composites using diamond coated tools with varied coating thicknesses was conducted to evaluate the effects on cutting forces, part surface finish and tool wear.

The results are summarized as follows. Increasing coating thickness will increase the residual stresses at the coating–substrate interface. On the other hand, increasing coating thickness will generally increase the resistance of coating cracking and delamination. Thicker coatings will result in larger edge radii; however, the extent of the effect on cutting forces also depends upon the machining condition. For the thickness range tested, the life of diamond coated tools increases with the coating thickness because of delay of delaminations. Keywords: Coating thickness; Diamond coating; Finite element; Machining; Tool wear

1. Introduction

Diamond coatings produced by chemical vapor deposition (CVD) technologies have been increasingly explored for cutting tool applications. Diamond coated tools have great potential in various machining applications and an advantage in fabrications of cutting tools with complex geometry such as drills. Increased usages of lightweight high-strength components have also resulted in significant interests in diamond coating tools. Hot-filament CVD is one of common processes of diamond coatings and diamond films as thick as 50 μm have been deposited on various materials including cobalt-cemented tungsten carbide (WC-Co) . There have also been different CVD technologies, e.g., microwave plasma assisted CVD , developed to enhance the deposition process as well as the film quality too. However, despite the superior tribological and mechanical properties, the practical applications of diamond coated tools are still limited.

Coating thickness is one of the most important attributes to the coating system performance. Coating thickness effects on tribological performance have been widely studied. In general, thicker coatings exhibited better scratch/wear resistance performance than thinner ones due to their better load-carrying capacity. However, there are also reports that claim otherwise and . For example, Dorner et al. discovered, that the thickness of diamond-like-coating (DLC), in a range of 0.7–3.5 μm, does not influence the wear resistance of the DLC–Ti6Al4V . For cutting tool applications, however, coating thickness may have a more complicated role since its effects may be augmented around the cutting edge. Coating thickness effects on diamond coated tools are not frequently reported. Kanda et al. conducted cutting tests using diamond-coated tooling . The author claimed that the increased film thickness is generally favorable to tool life. However, thicker films will result in the decrease in the transverse rupture strength that greatly impacts the performance in high speed or interrupted machining. In addition, higher cutting forces were observed for the tools with increased diamond coating thickness due to the increased cutting edge radius. Quadrini et al. studied diamond coated small mills for dental applications . The authors tested different coating thickness and noted that thick coatings induce high cutting forces due to increased coating surface roughness and enlarged edge rounding. Such effects may contribute to the tool failure in milling ceramic materials. The authors further indicated tools with thin coatings results in optimal cutting of polymer matrix composite . Further, Torres et al. studied diamond

coated micro-endmills with two levels of coating thickness . The authors also indicated that the thinner coating can further reduce cutting forces which are attributed to the decrease in the frictional force and adhesion.

Coating thickness effects of different coating-material tools have also been studied. For single layer systems, an optimal coating thickness may exist for machining performance. For example, Tuffy et al. reported that an optimal coating thickness of TiN by PVD technology exists for specific machining conditions . Based on testing results, for a range from 1.75 to 7.5 μm TiN coating, thickness of 3.5 μm exhibit the best turning performance. In a separate study, Malik et al. also suggested that there is an optimal thickness of TiN coating on HSS cutting tools when machining free cutting steels . However, for multilayer coating systems, no such an optimum coating thickness exists for machining performance .

The objective of this study was to experimentally investigate coating thickness effects of diamond coated tools on machining performance — tool wear and cutting forces. Diamond coated tools were fabricated, by microwave plasma assisted CVD, with different coating thicknesses. The diamond coated tools were examined in morphology and edge radii by white-light interferometry. The diamond coated tools were then evaluated by machining aluminum matrix composite in dry. In addition, deposition thermal residual stresses and critical load for coating failures that affect the performance of diamond coated tools were analytically examined.

2. Experimental investigation

The substrates used for diamond coating experiments, square-shaped inserts (SPG422), were fine-grain WC with 6 wt.% cobalt. The edge radius and surface textures of cutting inserts prior to coating was measured by a white-light interferometer, NT1100 from Veeco Metrology.

Prior to the deposition, chemical etching treatment was conducted on inserts to remove the surface cobalt and roughen substrate surface. Moreover, all tool inserts were ultrasonically vibrated in diamond/water slurry to increase the nucleation density. For the coating process, diamond films were deposited using a high-power microwave plasma-assisted CVD process.

A gas mixture of methane in hydrogen, 750–1000 sccm with 4.4–7.3% of methane/hydrogen ratio, was used as the feedstock gas. Nitrogen gas, 2.75–5.5 sccm, was inserted to obtain nanostructures by preventing columnar growth. The pressure was about 30–55 Torr and the substrate temperature was about 685–830 °C. A forward power of 4.5–5.0 kW with a low deposition rate obtained a thin coating; a greater forward power of 8.0–8.5 kW with a high

deposition rate obtained thick coatings, two thicknesses by varying deposition time. The coated inserts were further inspected by the interferometer.

A computer numerical control lathe, Hardinge Cobra 42, was used to perform machining experiments, outer diameter turning, to evaluate the tool wear of diamond coated tools. With the tool holder used, the diamond coated cutting inserts formed a 0° rake angle, 11° relief angle, and 75° lead angle. The workpieces were round bars made of A359/SiC-20p composite. The machining conditions used were 4 m/s cutting speed, 0.15 mm/rev feed, 1 mm depth of cut and no coolant was applied. The selection of machining parameters was based upon previous experiences. For each coating thickness, two tests were repeated. During machining testing, the cutting inserts were periodically inspected by optical microscopy to measure the flank wear-land size. Worn tools after testing were also examined by scanning electron microscopy (SEM). In addition, cutting forces were monitored during machining using a Kistler dynamometer.

5. Conclusions

In this study, the coating thickness effects on diamond coated cutting tools were studied from different perspectives. Deposition residual stresses in the tool due to thermal mismatch were investigated by FE simulations and coating thickness effects on the interface stresses were quantified. In addition, indentation simulations of a diamond coated WC substrate with the interface modeled by the cohesive zone were applied to analyze the coating system failures. Moreover, diamond coated tools with different thicknesses were fabricated and experimentally investigated on surface morphology, edge rounding, as well as tool wear and cutting forces in machining. The major results are summarized as follows.

(1) Increase of coating thickness significantly increases the interface residual stresses, though little change in bulk surface stresses.

(2) For thick coatings, the critical load for coating failure decreases with increasing coating thickness. However, such a trend is opposite for thin coatings, for which radial cracking is the coating failure mode. Moreover, thicker coatings have greater delamination resistance.

(3) In addition, increasing the coating thickness will increase the edge radius. However, for the coating thickness range studied, 4–29 μm, and with the large feed used, cutting forces were affected only marginally.

(4) Despite of greater interface residual stresses, increasing the diamond coating thickness, for the range studied, seem to increase tool life by delay of coating delaminations.

Acknowledgements

This research is supported by National Science Foundation, Grant No.: CMMI 0728228. P. Lu provided assistance in some analyses.

金刚石涂层刀具的涂层厚度的影响

作者：F. Qin, Y.K. Chou,D. Nolen and R.G. Thompson

发表日期：2009

摘要：

化学气相沉积法（CVD），金刚石薄膜的发现，作为涂层刀具的应用。即使传统的金刚石涂层的使用似乎是公认的切削，为不同的加工操作选择适当的涂层厚度没有经常研究。涂层厚度影响涂层刀具在不同的角度，可能相互影响，在复杂的方式，在机械加工工具金刚石工具的性能特点。

在这项研究中，在沉积层厚度对残余应力，特别是围绕一个前沿，对涂层的破坏模式进行了数值研究。另一方面，刀具表面光滑涂层厚度的影响以及尖端的半径进行了实验研究。此外，铝基复合材料加工用金刚石涂层刀具涂层厚度变化进行了评估对切削力的影响，零件表面光洁度和刀具磨损。

结果归纳如下:: （一）增加涂层厚度，涂层残余应力，基体界面。（2）在另一方面，增加涂层厚度一般会增加涂层耐开裂和脱层。（3）厚涂层将在更大的优势半径的结果，但是，对切削力的影响程度还取决于加工条件。（4）的厚度范围内进行测试，对金刚石涂层刀具寿命与因分层延迟涂层厚度的增加。

关键词：涂层厚度、金刚石涂层、有限元、加工、刀具磨损

1、介绍

采用化学气相沉积金刚石涂层生产法（CVD）技术已被越来越多地探讨了刀具的应用。金刚石涂层刀具在不同的加工应用的巨大潜力和优势，如切削钻头几何形状复杂的工具捏造。轻质高强度部件的增加也导致惯例，在金刚石涂层工具的重大利益。热丝化学气相沉积金刚石涂层的是，厚度为50微米，对包括钴硬质合金（碳化钨钴）[1]碳化钨各种材料沉积金刚石薄膜被普遍进程之一。也有不同的化学气相沉积技术，如微波等离子体辅助CVD，发展到提高沉积过程以及电影的质量了。然而，尽管上级摩擦学和力学性能，金刚石涂层刀具的实际应用仍然有限。

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毕业设计说明书英文文献及中文翻译学院：专 2011年6月电子与计算机科学技术软件工程

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my friend and I are taking a , we are seeing a boy sit on the chair,he is crying,we go and ask him.“what’s the matter with you” he tell us“I can’t find my dog can you help me”.“yes,I can”.And we help him find his dong .oh it stay under the big tree! 今天我和我的朋友一起去散步。突然我们看见一个男孩坐在椅子上，他哭的很伤心。我们走过去问他：“你怎么了”。他告诉我们：“我的狗不见了，你们能帮我找到它吗”。“是的，我们能帮你找到你的狗”然后我们帮助他找到了他的狗，原来是它呆在一棵大树下。 day an old man siselling a big young man comes to the elephant and begins to look at it old man goes up to him and says inhis ear,“Don't sa y anything about the elephant before I sell it,then i'll give you some money.”“All right,”says the young the old man slles the elephant,he gives the young man some money and says,“Now,can you tell me how you find the bad ears of theelephant?”“I don't find the bad ears,”says the young man.“Then why do you look at the elephant slowly?”asks the old young man answers,“Because I never see an elephant before,and I want to know what it looks like.” 一天，一个老的男人正在卖一头大象。一个年轻的男人走向大象然后开始慢慢看着它（大象），这个老的男人走向他对着他的耳朵说，“不要在我卖出它（大象）之前说关于它（大象）的事，然后我会给你一些钱。”“好的”，这个年轻的男人说。在这个老的男人卖出大象后，他给了年轻的男人一些钱并且说，“现在，你可以告诉我你是怎样知道大象的坏的耳朵了吧？”“我不知道坏的耳朵”，这个年轻的男人说。“然后为什么你慢慢的看着大象？”这个老的男人问。这个年轻的男人回答，“因为我在这之前从来没有见过大象，还有我想知道它（大象）是什么样子的。” 3.An old woman had a cat. The cat was very old; she could not run quickly, and she could not bite, because she was so old. One day the old cat saw a mouse; she jumped and caught the mouse. But she could not bite it; so the mouse got out of her mouth and ran away, because the cat could not bite it.? Then the old woman became very angry because the cat had not killed the mouse. She began to hit the cat. The cat said, "Do not hit your old servant. I have worked for you for many years, and I would work for you still, but I am too old. Do not be unkind to the old, but remember what good work the old did when they were young."? 一位老妇有只猫，这只猫很老，它跑不快了，也咬不了东西，因为它年纪太大了。一天，老猫发现一只老鼠，它跳过去抓这只老鼠，然而，它咬不住这只老鼠。因此，老鼠从它的嘴边溜掉了，因为老猫咬不了它。? 于是，老妇很生气，因为老猫没有把老鼠咬死。她开始打这只猫，猫说：“不要打你的老仆人，我已经为你服务了很多年，而且还愿意为你效劳，但是，我实在太老了，对年纪大的不