Abstract
DLC coated tools have been widely utilized in the dry milling and cutting of aluminum alloy parts and components for automotive industries and cellular phone makers. Most of these tools are inevitably exchanged with new ones to preserve high quality of machined products. Then, the used DLC coating must be removed or ashed away before grinding and polishing. Complete removal of used DLC coating plays a key to make DLC-recoating onto the ashed surface of tools for their reuse. High density oxygen plasma ashing provides a solution to make perfect ashing of DLC coating together with metallic interlayers before recoating. In the present paper, this plasma system with quantitative diagnosis instrumentation is first stated to describe the effect of processing conditions on the ashing behavior. Two types of end-milling tools were prepared to prove that the whole DLC-coating should be completely removed with fast rate. This ashed tool substrate was ground and DLC-recoated to demonstrate that the reused tools have the same machinability in dry as the original virgin tools through dry milling experiments.
Highlights
The aluminum alloys have been widely utilized as a light-weight structural material with higher specific strength in the aircraft components and automotive parts for further reduction of CO2 emission in transportation (Cole, 1997)
The effective ashing rate of DLC coating from the tool substrate is determined by three processes: i.e. two ashing processes of DLC layer and metallic interlayers and a homogeneous ashing process of the whole tool surfaces
High density oxygen ashing system was developed and applied to make removal of DLC coating from DLC-coated milling tools for dry cutting of aluminum alloys
Summary
The aluminum alloys have been widely utilized as a light-weight structural material with higher specific strength in the aircraft components and automotive parts for further reduction of CO2 emission in transportation (Cole, 1997). In the above mass-productive machining, tool life extension becomes the first necessary condition to shorten the leading time with low production cost and to save materials and resource. The DLC film thickness was inevitably reduced by abrasive wear during dry milling or cutting. This suggests that the used DLC coating should be removed once for recoating the original tool substrates to reuse them. This recycling of tool substrate materials is indispensable to save the tool materials cost such as WC (Co) or super-alloys and to preserve the product surface quality with proof of originally tailored tool surfaces
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