Surface quality of cemented tungsten carbide finished by direct cutting using diamond-coated carbide end mill

Okada, Masato; Shinya, Masayoshi; Kondo, Atsuyuki; Watanabe, Hidehito; Sasaki, Toshihiko; Miura, Takuya; Otsu, Masaaki

doi:10.1016/j.jmapro.2020.11.004

Cited by 12 publications

(4 citation statements)

References 32 publications

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“…An investigation on end milling found that when cemented tungsten carbide is machined, the diamond coating on the rake face flaking immediately after milling starts. Moreover, a sharp cutting edge was created on the diamond coating ridge remained on the flank face, resulting in good cutting performance and finishing surface quality (Okada et al, 2016;Okada et al, 2019a;Okada et al, 2021). Furthermore, when cemented tungsten carbide was drilled using a diamond-coated carbide drill, a similar change in the cutting-edge shape was observed, resulting in a reduction in the thrust force (Okada et al, 2019b).…”

Section: Introductionmentioning

confidence: 99%

Through-hole drilling characteristics of alumina ceramics using diamond-coated carbide drill

OKADA,

HIRATA,

WATANABE

et al. 2024

JAMDSM

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The drilling characteristics of alumina ceramics during through-hole drilling with a diamond-coated carbide drill were investigated experimentally. The drilling characteristics were evaluated by cutting edge behavior, cutting force (thrust force and torque), and chipping state at the exit side of the drilled hole in relation to the number of drilled holes. Additionally, the effects of the diamond-coating thickness and drill feed rate were investigated. The drills had a typical twist shape and were made of tungsten carbide base material with diamond coatings at 10 µm and 20 µm thick. The drilling machine was a standard machining center with a simple unidirectional drill feed without vibration. In through-hole drilling, as in blind-hole drilling, the coating on the rake face flaked during the initial stage of drilling, resulting in a sharp cutting edge on the diamond-coating ridge remaining on the flank face. However, flaking of the diamond coating on the rake face was observed earlier during through-hole drilling than in blind-hole drilling. Although the chipping area increased with increasing drill feed rate, coating flaking on the rake face significantly suppressed it at all feed rates. There was a clear correlation between the chipping area and cutting force since the chipping area decreased with decreasing thrust force. Before the theoretical hole penetration, hat-shaped chipping was observed with two crack propagation directions, accompanied by a sharp decrease in thrust force. Moreover, even after observing a sharp decrease in thrust force, a gradual decrease in thrust force was observed in the case of a good chipping state. The chipping area was significantly improved by reducing the coating thickness, and the thrust force was reduced.

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Section: Introductionmentioning

confidence: 99%

Through-hole drilling characteristics of alumina ceramics using diamond-coated carbide drill

OKADA,

HIRATA,

WATANABE

et al. 2024

JAMDSM

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“…With the action of atomic hydrogen, a serious of adsorption and desorption reactions of these groups will occur, leading to the nucleation and growth of a diamond film on the substrate surface. [4][5][6][7][8] In recent years, the development and application of diamond-coated tools was explored by several researchers. The cutting performance of diamond-coated WC-Co tools was demonstrated to be greatly superior to the uncoated tools.…”

Section: Introductionmentioning

confidence: 99%

Cutting Performance and Wear Mechanism of Multilayer Diamond‐Coated Tools

et al. 2023

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Monolayer and multilayer diamond films are deposited on WC‐Co cemented carbide by hot‐filament chemical vapor deposition. The growth characteristics of diamond coatings are analyzed. Cutting performance characteristics such as tool life and the stability of machining process in the machining of presintered ZrO2 are compared based on the variation of cutting speed and resultant cutting force, and workpiece surface roughness. For the monolayer diamond coatings, as the concentration of CH4 increases from 1% to 5%, the diamond crystal is transformed from micron columnar crystal to nanocluster crystal. The multilayer diamond coatings combine the advantages of micron‐ and nanocrystalline structures. The multilayer diamond‐coated tool exhibits longer service life and better machining quality. Because of the appearance of the brittle–plastic conversion mechanism, the surface integrity of ZrO2 processed by multilayer diamond‐coated tool is relatively high. As for the uncoated tool, the workpiece is mainly machined by brittle spalling. The interfacial stratified fracture system between the interlayers is proposed to be the toughening mechanism of the multilayer structure.

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“…The authors report the negative impact of feed rates higher than the cross sectional thickness of the coating film and the importance of keeping feed rates bellow such values for maximizing tool durability. Focusing on the surface quality of cemented carbide, Okada et al [26] have compared direct cutting using diamond-coated carbide end mill with two di↵erent common processing routes of cemented carbide: mechanical polishing and electric discharge machining (EDM). Despite having found that identical mirror-like finish to mechanical polishing can be obtained via direct cutting, finished surface resulting from direct cutting were comparatively rougher than those resulting from mechanical polishing (and roughner than EDM).…”

Section: Introductionmentioning

confidence: 99%

Investigation on micro milling of cemented carbide with ball nose and corner radius diamond coated end mills

Figueiredo,

Silva,

Silva

et al. 2023

Preprint

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Micro milling of cemented carbides is a challenging task due to their high hardness, low toughness and high wear resistance. Ensuring good surface quality and dimensional accuracy is crucial for extending parts service life, which in turn enhances economical and environmental sustainability. This paper is mainly focused on evaluating surface formation mechanisms, scale effects, fracture behaviour and chip formation using distinct cemented carbide micro milling tools with multi layer diamond HF-CVD. In order to achieve higher precision and more efficient micro milling operations on WC-15Co and WC-10Co, a systematic experimental approach has been carried out. The influence of cutting parameters, achievable surface quality and defects occurrence were thoroughly examined. Experimental results evidence the influence of operational conditions on the chip formation of cemented carbides as well as an important impact of the utilized cutting tool. Micro pits, cracks, thin ploughing layer and fractured workpiece edges are amongst the observed surface damage mechanisms. A ductile cutting regime of the high-hardness composite material is confirmed, exhibited by the plastic deformation even when small depths of cut are considered.

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Surface quality of cemented tungsten carbide finished by direct cutting using diamond-coated carbide end mill

Cited by 12 publications

References 32 publications

Through-hole drilling characteristics of alumina ceramics using diamond-coated carbide drill

Through-hole drilling characteristics of alumina ceramics using diamond-coated carbide drill

Cutting Performance and Wear Mechanism of Multilayer Diamond‐Coated Tools

Investigation on micro milling of cemented carbide with ball nose and corner radius diamond coated end mills

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