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Diamond coatings will be widely used in the field of cutting
Abstract Tool coatings are not only designed to extend the lifespan of cutting tools, but also to reduce or eliminate the need for cutting fluids. Additionally, they should provide self-lubricating properties. Diamond-like carbon (DLC) coatings have shown significant advantages in machining specific materials such as AlTi and its composite alloys. However, after years of research, it has been found that DLC coatings suffer from high internal stress, poor thermal stability, and a catalytic effect with ferrous metals, which can cause the SP3 structure to transition into an SP2 structure. These limitations restrict their application mainly to non-ferrous metals, thereby limiting their broader use in machining processes.
In recent years, new types of DLC coatings—often referred to as graphite-like coatings—have gained attention. These coatings possess a hardness of up to 2040 GPa, do not react with ferrous metals, exhibit a very low friction coefficient, and have excellent moisture resistance. They are suitable for dry cutting applications and have proven to outperform uncoated tools in terms of tool life, sometimes doubling it. This makes them ideal for machining steel materials, sparking interest among coating companies and tool manufacturers. Over time, this advanced type of DLC coating is expected to become widely adopted in the cutting industry.
As material performance requirements continue to rise, various vapor deposition technologies have emerged over the past few decades, driven by advancements in science and technology. The development and application of surface engineering techniques have progressed rapidly. These technologies not only meet mechanical performance needs like wear resistance, friction reduction, and corrosion protection, but also address electromagnetic, optical, optoelectronic, thermal, superconducting, and biological functions. Surface engineering helps unlock the potential of low-cost metal materials and serves as a key method for developing new coating materials, offering great application potential.
Modern machining demands higher tool performance. Beyond extending tool life, there is a growing emphasis on reducing environmental pollution during cutting. As the machining industry advances, dry cutting is increasingly preferred. When cutting fluids cannot be entirely avoided, it is recommended to use fluids containing only rust inhibitors and no organic compounds, significantly reducing recycling costs.
Milling cutters must also account for their intermittent impact characteristics. Early coatings focused primarily on wear resistance, but the diverse working conditions of cutting tools require careful selection of coating materials. For example, turning and drilling involve different operational demands. In some cases, improving hardness is the primary goal. Titanium nitride is a classic example of such coatings, though it has a relatively high friction coefficient (ranging from 0.4 to 0.6). Frequent friction between the tool and workpiece generates significant heat, which can lead to tool deformation and affect machining accuracy. To prevent this, cutting fluids are typically used to maintain tool integrity and prolong its service life.