Study of cutting force and tool wear during turning of aluminium with WC, PCD and HFCVD coated MCD tools

Sisira Kanta Pattnaik,Sachidananda Padhi,Minaketan Behera,Pusparaj Dash,Saroj Kumar Sarangi

doi:10.1051/mfreview/2020026

Sisira Kanta Pattnaik, Sachidananda Padhi + Show 3 more

Open Access

https://doi.org/10.1051/mfreview/2020026

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Abstract

Enormous developmental work has been made in synthesis of metastable diamond by hot filament chemical vapor deposition (HFCVD) method. In this paper, micro-crystalline diamond (MCD) was deposited on WC–6 wt.% Co cutting tool inserts by HFCVD technique. The MCD coated tool was characterized by the scanning electron microscope (SEM), X-ray diffraction (XRD) and micro Raman spectroscopy (μ-RS). A comparison was made among the MCD tool, uncoated tungsten carbide (WC) tool and polycrystalline diamond (PCD) tool during the dry turning of rolled aluminum. The various major tests were conducted such as surface roughness, cutting force and tool wear, which were taken into consideration to establish a proper comparison among the advanced cutting tools. Surface roughness was measured during machining by Talysurf. The tool wear was studied by SEM after machining. The cutting forces were measured by Kistler 3D-dynamometer during the machining process. The test results indicate that, the CVD coated MCD tool and PCD tool produced almost similar results. But, the price of PCD tools are five times costlier than MCD tools. So, MCD tool would be a better alternative for machining of aluminium.

Highlights

Diamond is the hardest available material till date
micro-crystalline diamond (MCD) film was deposited on WC cutting tool inserts for turning aluminium
At high speed and low feed rate, it showed promising results. – Regarding force measurement, a minimum cutting force was produced while machining with the MCD cutting tool which is an indication of providing maximum tool life. – The analysis of tool wear represents that, the wear occurred on the Polycrystalline Diamond (PCD) tool was less compared to MCD and WC tools

Summary

Introduction

Diamond is the hardest available material till date. The low-pressure synthesis of diamond was reported for 1st time in 1961 (Eversole; Union carbide corporation) CVD is one of the important techniques to produce diamond on the substrate. The substrate might be a cutting tool or any commercial or medical application material. There are different CVD techniques like lowpressure CVD (LPCVD); atmospheric pressure CVD (APCVD) and plasma enhanced CVD (PECVD), etc. The LPCVD is very much popular and preferable technique to produce diamond, due to its excellent purity, uniformity and good step coverage [2]. The deposition is with very good in LPCVD with uniform step coverage throughout the substrate. In the case of poor step coverage, there is very less deposition on the

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