Fabrication, tribological properties and cutting performances of high-quality multilayer graded MCD/NCD/UNCD coated PCB end mills

Wang, Hua; Song, Xin; Wang, Xinchang; Sun, Fei

doi:10.1016/j.diamond.2021.108505

Cited by 21 publications

(5 citation statements)

References 34 publications

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“…The performance of the monolayer NCD films falls somewhere between MCD and UNCD [ 53 , 109 , 110 , 111 ]. Wang et al [ 112 ] prepared various diamond films (used for fabrication of diamond end mills) using the HFCVD technique on cobalt sintered tungsten carbide (WC-Co6%) substrates, including single-layer MCD, single-layer NCD, single-layer UNCD, double-layer MCD/NCD, double-layer MCD/UNCD and multilayer MCD/NCD/UNCD. In these developed diamond materials, an NCD or UNCD film is fabricated onto the cutting edge, exhibiting excellent chip evacuation capabilities, wear resistance and extending the mill’s life during high-speed machining.…”

Section: Ncd For Tribological Applicationsmentioning

confidence: 99%

“… ( A ) Curves of COFs and ( B ) average wear rates of different diamond films against SiC balls. ( C ) Comparisons of SEM images(a1,b1,c1,d1,e1,f1) and EDS mapping(a1,a2; b1,b2; c1,c2; d1,d2; e1,e2; f1,f2) of the transfer film formed on the frictional zones for different polycrystalline diamond coatings of (a) MCD; (b) NCD; (c) UNCD; (d) MCD/NCD;(e) MCD/UNCD; (f) MCD/NCD/UNCD [ 112 ]. Adapted with permission.…”

Section: Figurementioning

confidence: 99%

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Application of Nano-Crystalline Diamond in Tribology

Xia

Yang

et al. 2023

Materials

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Nano-crystalline diamond has been extensively researched and applied in the fields of tribology, optics, quantum information and biomedicine. In virtue of its hardness, the highest in natural materials, diamond outperforms the other materials in terms of wear resistance. Compared to traditional single-crystalline and poly-crystalline diamonds, nano-crystalline diamond consists of disordered grains and thus possesses good toughness and self-sharpening. These merits render nano-crystalline diamonds to have great potential in tribology. Moreover, the re-nucleation of nano-crystalline diamond during preparation is beneficial to decreasing surface roughness due to its ultrafine grain size. Nano-crystalline diamond coatings can have a friction coefficient as low as single-crystal diamonds. This article briefly introduces the approaches to preparing nano-crystalline diamond materials and summarizes their applications in the field of tribology. Firstly, nano-crystalline diamond powders can be used as additives in both oil- and water-based lubricants to significantly enhance their anti-wear property. Nano-crystalline diamond coatings can also act as self-lubricating films when they are deposited on different substrates, exhibiting excellent performance in friction reduction and wear resistance. In addition, the research works related to the tribological applications of nano-crystalline diamond composites have also been reviewed in this paper.

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Section: Ncd For Tribological Applicationsmentioning

confidence: 99%

Section: Figurementioning

confidence: 99%

Application of Nano-Crystalline Diamond in Tribology

Xia

Yang

et al. 2023

Materials

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“…Several researchers suggested the use of nano-structured coatings. The friction properties of high-quality multi-layer nano diamond gradient microcrystalline diamond/ nanocrystalline diamond/ ultrananocrystalline diamond (MCD/NCD/UNCD) coated end mills exceeded those of single-layer coatings [184]. In addition, the effects of the nanolayer thickness in Ti-TiN-(Ti,Al,Cr)N coatings on the friction properties were also evaluated, indicating that the friction coefficient appeared as a non-monotonic variation and a nanolayer thickness of 16 nm provided the lowest friction coefficient [185].…”

Section: Tool Coatingsmentioning

confidence: 99%

Friction behaviors in the metal cutting process: state of the art and future perspectives

Liang

Wang

et al. 2022

Int. J. Extrem. Manuf.

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Material removal in the cutting process is regarded as a friction system with multiple input and output variables. The complexity of cutting friction system is caused by the extreme conditions existing on the tool-chip and tool-workpiece interfaces. The key issue is extremely important to use knowledge of cutting friction behaviors to guide researchers and industrial manufacturing engineers in designing reasonable cutting processes to reduce tool wear and improve surface quality. This review focuses on the state of the art of research on friction behaviors in cutting processes as well as future perspectives. First, the cutting friction phenomena under extreme conditions, such as high temperature, large strain/strain rates, sticking-sliding contact states, and diverse cutting conditions are analyzed. Second, the theoretical models of cutting friction behaviors and the application of simulation technology are discussed. Third, the factors that affect friction behaviors are analyzed including material matching, cutting parameters, lubrication/cooling conditions, micro/nano surface textures and tool coatings. Then, the consequences of the cutting friction phenomena including tool wear patterns, tool life, chip formation, and the machined surface are analyzed. Finally, the research limitations and future work for cutting friction behaviors are discussed. This review contributes to the understanding of cutting friction behaviors and the development of high-quality cutting technology.

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“…The typical edge diameter range of milling tools for high-level PCB is 0.5 to 2.5 mm, and the cutting part’s cross-sectional size is small. The lack of a bonding phase brought on by the substrate surface’s de-cobaltization will significantly reduce the cutting edge’s toughness, which in turn will affect the tool’s cutting performance [ 15 ]. Therefore, in order not to significantly damage the fracture strength of micro-cutting tools, the optimization of the substrate pretreatment process parameters and the enhancement of the film–substrate bond strength need to be investigated in depth.…”

Section: Introductionmentioning

confidence: 99%

Effect of Substrate Pretreatment Process on the Cutting Performance of Diamond-Coated PCB Micro-Milling Tools

Yang

Lin

et al. 2022

Micromachines

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Diamond coatings were deposited on PCB (printed circuit board) carbide milling tool substrates under various schemes of acid and alkali pretreatment by hot filament chemical vapor deposition (HFCVD). Scanning electron microscopy and X-ray coating analysis were used to examine the surface morphology of the milling tools and the impact of de-cobalt from the substrate surface after pretreatment. Milling experiments were carried out to study the cutting performance of diamond-coated PCB micro-milling tools under various pretreatment processes. The results show that abrasive wear, coating flaking, and cutting-edge chipping are the main failure forms of coated PCB milling tools. The substrate pretreatment process with 20 min of alkali etching followed by 20 s of acid etching allows the diamond-coated micro-milling tools to produce the best film–substrate adhesion and substrate strength. These milling tools also have the longest service lives and are suitable for the high-speed cutting processing of PCB.

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Fabrication, tribological properties and cutting performances of high-quality multilayer graded MCD/NCD/UNCD coated PCB end mills

Cited by 21 publications

References 34 publications

Application of Nano-Crystalline Diamond in Tribology

Application of Nano-Crystalline Diamond in Tribology

Friction behaviors in the metal cutting process: state of the art and future perspectives

Effect of Substrate Pretreatment Process on the Cutting Performance of Diamond-Coated PCB Micro-Milling Tools

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