Abstract
The ideal cutting-tool coating material is characterized by unique chemical and physical properties to achieve excellent cutting performance, a good thermal barrier effect, and a high-quality machined surface. Diamond-like carbon (DLC) coating, as a kind of cutting-tool coating material, has been used in cutting various materials due to its low coefficients of friction and thermal expansion, high hardness, and good chemical inert and thermal conductivity. This article mainly focuses on the modification methods for the DLC coating and their application in machining different materials. Firstly, the methods employed to improve the mechanical properties of DLC coating are reviewed and analyzed, including the multilayer structure design, transition layer, and doping other elements. Secondly, the machining performances of DLC-coated tools in the application of different materials are summarized. This review provides knowledge of modification mechanisms regarding DLC coating and its effects on mechanical properties. For machining different materials, it provides a reference to make a suitable selection and design of DLC coating to obtain better machining performance.
Highlights
Diamond-like carbon (DLC) films originally entered the machining field as a cutting-tool coating material in the 1990s, satisfying the modern manufacturing requirements of superior hardness and toughness, excellent wear resistance and a low coefficient of friction (CoF), which contributed to enhancing the adaptability and durability of cutting tools [25,26]
Narguess Nemati et al [34] introduced a multilayered WC/DLC coating with the combination of super-high hardness (>45 GPa), high H/E (~0.15), low compressive residual stress (
For the W-incorporated DLC coatings (W-DLC) coating with W concentration between 2.8 and 3.6 at.%, the crystalline carbon were not changed by the introduction of W atoms, which results in the hardness
Summary
As a metal processing technology, cutting involves three main procedures of local plastic deformation, fracture and chip removal to obtain a targeted geometry and shape, generating a large amount of stress, strain, and heat accumulation [1]. A BUE involves the chip adhering to the cutting-edge under high force and heat, especially in machining lightweight alloys. The fatigue fracture occurs at BUE and forms abrasive particles because of cyclical stress under the contact with the workpiece, which accelerates cutting-tool wear, destroying the cutting-edge profile and deteriorating the surface finish quality of the workpiece, affecting the dimensional precision of the machined part [1]. The surface quality and dimensional precision of the workpiece are crucial evaluation indicators for the cutting process, which is correlated with BUE formation and with the tool edge radius. Cutting tools wear quickly at at the initial stage because of the high stress induced by the rough surface of the tools. Elevated cutting force and heating accumulation cause excessive tool-edge wear at the third stage.
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