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HCHNOLOGY
Research and Development Division, Nachi-Fujikoshi Corp., 20 Ishigane, Toyama City, Toyama 930, Japan
b Tools Division, Nachi-Fujikoshi Corp., 20Ishigane, Toyama City, Toyama 930, Japan
Abstract
Today, diamond-coated cutting tools are used primarily for machining non-ferrous materials such as aluminium-silicon alloys,
copper alloys, fibre-reinforced polymers, green ceramics and graphite. The tool life of cemented carbide cutting tools is greatly
improved by diamond coating, and typically more than 10 times the tool life is obtained. In this report we will present cutting
performances of diamond-coated inserts, twist drills, square end mills and ball nose end mills.
Diamond films are usually deposited more than 10 J.U11 thick to make tool life longer, since tool life is directly related to film
thickness. However, increased film thickness caused many problems with cutting performance. The most severe problem was the
decrease in the transverse rupture strength of the diamond-coated substrates. Because of this effect, the diamond-coated insert
used under high speed and intermittent cutting conditions was supposed to suffer chipping easily.
Keywords: Diamond-coated cutting tool; Insert; Twist drill; End mill; Cutting performance
1. Introduction
Metallurgical
Coatings and Thin Films, San Diego, CA, 25-29 April 1994.
116
60
Work
:
Cut speed :
Depth of cut:
Feed rate
:
50
A390
330 m/min
n.5 mm
n.15 mm/rev
ing was also carried out with the same type of high
pressure polycrystalline diamond (PCD) insert, since
PCD inserts are thought to be the strongest competitor
for diamond-coated inserts.
The result of the face milling test is shown in Fig. 1.
From this figure, the wear rate of the diamond-coated
insert is found to be comparable with that of the peD
insert. The flank wear of the diamond-coated insert
became large compared with that of the PCD insert at
the beginning of the cut. This was due to the increased
roundness of the coated edge, since scars became large
at the edge radius and flank wear was scaled by measur
ing scars that appeared on the cutting edge.
A turning test was also carried out on the A390
material with the same type of diamond-coated insert
and a fine-grained PCD insert. The initial radius of the
A390 workpiece was 200 mm with four slots cut of
10 mm width along the axial direction to simulate
intermittent cutting. Cutting parameters were as follows:
cutting speed, 400 m min -I; depth of cut, 0.2 mm; feed
rate, 0.15 mm rev-I; dry cutting. This test lasted 240 min
without any trouble. The result showed approximately
the same wear tendency as that of face milling.
Although results are not shown in Fig. 1, the uncoated
cemented carbide inserts were also tested by face milling
and turning, but their flank wear exceeded 150 Jlm after
a 1 min cutting period.
In the case of the diamond-coated insert, which has
11 0 clearance angle and 25 Jlm film thickness, substrate
material is exposed after the flank wear exceeded approx
imately 40 Jlm. After that the end of tool life will come
soon, since the substrate material is worn away quickly
for A390 alloy. Therefore, the tool life of a diamond_
coated insert with ordinary film thickness will never be
greater than that of PCD. We believe the superiority of
Tip: SPGNI20308
Blade: 1 pc
Dry cut
DiatnOnd coat.\illn~g_-<::r-_-O-~~-:::~
J
;0
.b- - -
.t:r
--~-
~;o
-A--- ~---
20
10
r ....
A_;O
_...t:r - - l' CD
.A---~
I
I
50
100
150
200
250
117
12' r---,r---'--.-~-~-.,...--r-,.---r--,
e
::t
..".
,,
e::t
Work P'_
: A390
Revolution
Feed rate
: 4250 rpm
: 0.1 mmlrev
e"
Hole depth
Cemenled carbide
Coolant
: 10 mm
: ""Iter-soluble emulSion
Diamond coating
4000
2000
3000
Number of processed holes
2000
3000
4000
5000
1000
,, Cemenled carbide
1000
,,
... '
10
Diamond coating
...1
15
Workpi_
: A390
Drill dllmeter : 3.0mm
Revolution
4250 rpm
Feed rale
01 mmJrev
Hole depth
: 10mm
Coolant
: water-soluble emulsion
10
5000
Table I
Comparison of the tool life between diamond-coated and uncoated cemented carbide twist drills
Diameter
(mm)
2.5
6.0
3.0
1.5
Workpiece
material
ADCI2
A390
GFRP
Semisintered WC-Co
Thickness
or depth
(mm)
5
20
3
2
Tool life
Cutting parameter
WC-Co
(holes)
Diamond coat
(holes)
Revolution
(rev min -1)
Feed rate
(mm rev-I)
2oo
25S000
S075
2oo
3oo
4oo
14000
1000
O.OS
0.20
0.0125
0.01
160
3000
100
2100
118
Fig. 4. Cutting edges of (a) the diamond-coated twist drill after 2100
holes and (b) the uncoated cemented carbide twist drill after 525 holes.
1.2
(a)
1.0
Z
c
Vi 0.6
, ,
..r::
f-o
_
Diamond coating
- - - Cemented carbide
0.8
.,.
,
.,. .,.
.,. .,.
.,.
.,. ,.,---
0.4
0.2
0
0.1
0.15
0.2
0.25
(b)
1.6
Diamond coating
- - - Cemented carbide
1.4
E
.,
"~
---
1.2
1.0
0.8
0.6
0.4
0.2
0
0.1
0.15
0.2
0.25
Fig. 6. Photographs of the outer cutting edge: (a) before and (b) after
grinding the diamond films.
60
Workpiece
Diameter
50
Feed rate
Axial d.o.c.
:l
...[ij
Ii:
Revolution
8mm
8000 rpm
2m1mon
Radil.l d.D.C. :
14mm
O.2mm
dry
Coolant
::I.
A390
40
30
20
10
0
r"'
carbide
Diamond coaling
200
100
300
400
Workpiece
Nose radius
300
Revolution
Axial d.o.c.
Radial d.o.c.
:::t
..
'-'
200
Cernenled carbide
-"l
l;j
ti:
119
100
OL----L._........._'----L._........._'----L._........._'----L._....L.._'----L._....L.._'--........
1500
500
1000
o
Cutting distance (rn)
Fig. 8. Wear characteristics of the diamond-coated and the uncoated ball nose end mills.
120
Fig. 9. Cutting edge of ball nose end mills after milling test of graphite:
(a) rake face and (b) flank face of the diamond-coated ball nose end
mill; (c) rake face and (d) flank face of the uncoated ball nose end mill.
8-
2.2 f-
..c:
0:0
~"
2.0
""2
"
"'"
~
f-O~O
o~o
1.8 f1.6 f-
~O
a>
1.4 f1.2
10
20
Film thickness (tL m)
30
40
4. Conclusions
References
[1] S. Matsumoto, Y. Sato, M. Kamo and N. Setaka, lpn. J. Appl.
Phys., 21 (1982) Ll83.
[2] M. Kamo, Y. Sato, S. Matsumoto and N. Setaka, J. Cryst.
Growth, 62 (1983) 642.
[3] M. Murakawa, S. Takeuchi, H. Miyazawa and Y. Hirose, Surf
Coat. Technol., 36 (1988) 303.
[4] N. Kikuchi and H. Yoshimura, New Diamond, (1988) 42.
[5] J. Oakes, XX Pan, R. Haubner and B. Lux, Surf. Coat. Technol
47(1991)600.
.,
[ 6] K. Kanda, S. Takehana, S. Yoshida, F. Shimakura and K. Ishigane,
Proc. 2nd Int. Conf. on the Application of Diamond Films and
Related Materials, Ohmiya, MYU, Tokyo, 1993, p. 565.
[7] S. Takehana, S. Tsukao and K. Kanda, Proc. 2nd Int. Conf on
the Application of Diamond Films and Related Materials, Ohmiya,
MYU, Tokyo, 1993, p. 571.