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Improving nanocrystalline diamond coatings for micro end mills.

机译：改进用于微型立铣刀的纳米晶金刚石涂层。

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摘要

A new method is presented for coating 300 mum diameter tungsten carbide (WC) micro end mills with diamond using a hot filament chemical vapor deposition (HF-CVD) method. This method has been developed to create uniform, conformal and continuous diamond coatings. Initial work is shown to prove the feasibility and concept of the project. This was the first work known to coat and evaluate the machining performance WC micro end mills. The performance of uncoated and coated micro end mills was evaluated by dry machining channels in 6061-T6 aluminum. The test results showed a 75% and 90% decrease in both cutting and trust forces for machining, respectfully. The coated tools produced a more predictable surface finish with no burring. These improved results are due to the superior tribological properties of diamond against aluminum. Initial results indicated severe problems with coating delamination causing complete tool failure.;After proving the initial concept, new methods for optimizing the coating and improving performance were studied. Each optimization step is monitored through surface analysis techniques to monitor changes in coating morphology and diamond quality. Nucleation density was increased by improving the seed method, using ultra dispersed diamond (UDD) seed. The increase in nucleation density allowed the synthesis of coatings as thin as 60 nm. The adhesion of the coating to the tool was improved through carbon ion implantation (CII). CII is a different surface preparation technique that deactivates the effect of Co, while not weakening the tool. CII also creates a great nucleation layer which diamond can directly grow from, allowing the diamond coating to chemically bond to the substrate improving adhesion and eliminating the need for a seed layer. These thin coatings were shown to be of high quality sp3 trigonaly bonded diamond that resulted in lower machining forces with less delamination.;The 90% reduction in machining forces that thin conformal diamond coatings can achieve for micro end mills directly influences the accuracy of parts and the speed with which they can be made. A 50% reduction in forces could be used to double the material removal rate, cutting the part machining cost in half.
机译：提出了一种使用热丝化学气相沉积（HF-CVD）方法在300毫米直径的碳化钨（WC）微型立铣刀上涂覆金刚石的新方法。已经开发出该方法以产生均匀，共形和连续的金刚石涂层。初步工作证明了该项目的可行性和概念。这是涂覆和评估WC微型立铣刀加工性能的第一项工作。通过在6061-T6铝中干式加工通道来评估未涂覆和涂覆的微型立铣刀的性能。测试结果表明，切削力和机械加工信任度分别降低了75％和90％。涂层工具可产生更可预测的表面光洁度，且无毛刺。这些改进的结果归因于金刚石对铝的优越的摩擦学性能。初步结果表明，涂​​层分层严重问题导致工具彻底失效。；在证明了最初的概念之后，研究了优化涂层和改善性能的新方法。每个优化步骤均通过表面分析技术进行监控，以监控涂层形态和金刚石质量的变化。通过使用超分散金刚石（UDD）种子改进种子方法，可以提高成核密度。成核密度的增加允许合成厚度低至60 nm的涂层。通过碳离子注入（CII）改善了涂层对工具的附着力。 CII是另一种表面处理技术，可在不削弱工具的情况下使Co的作用失效。 CII还创建了一个巨大的成核层，金刚石可以直接从该成核层生长，从而使金刚石涂层能够化学键合到基材上，从而提高附着力并消除了对晶种层的需求。这些薄涂层被证明是高质量的sp3三角结合金刚石，从而导致较低的机械加工力和更少的分层。;对于微型立铣刀而言，薄形共形金刚石涂层可实现的加工力降低90％直接影响零件的精度和它们的制造速度。减少50％的力可以使材料去除率提高一倍，从而将零件加工成本降低一半。

著录项

  • 作者

    Heaney, Patrick J.;

  • 作者单位

    The University of Wisconsin - Madison.;

  • 授予单位 The University of Wisconsin - Madison.;
  • 学科 Engineering Mechanical.;Engineering Materials Science.
  • 学位 Ph.D.
  • 年度 2009
  • 页码 183 p.
  • 总页数 183
  • 原文格式 PDF
  • 正文语种 eng
  • 中图分类
  • 关键词

  • 入库时间 2022-08-17 11:38:19

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