微米及纳米金刚石涂层扁钻的制备及其切削性能
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摘要
目的研究微米金刚石薄膜(Microcrystalline diamond film,MCD film)和纳米金刚石薄膜(Nanocrystalline diamond film,NCD film)的微观组织结构和表面质量,以及由两种薄膜涂覆制成的微米金刚石涂层扁钻(MCD coated spade drill)和纳米金刚石涂层扁钻(NCD coated spade drill)在切削碳纤维增强复合材料(Carbon fiber reinforced plastics,CFRP)时的切削性能。方法采用热丝化学气相沉积法在硬质合金扁钻上分别制备MCD薄膜和NCD薄膜。使用扫描电子显微镜观察金刚石薄膜的表面和横截面形貌,利用白光干涉表面轮廓仪测量薄膜的表面粗糙度值,使用拉曼光谱仪检测薄膜的结构成分,利用X射线衍射仪(XRD)检测薄膜的晶体结构和晶面取向,通过切削实验分析无涂层刀具和微、纳米涂层刀具的切削性能。结果制成的MCD和NCD薄膜涂覆均匀,两种薄膜的厚度都为8μm,晶面取向均以(111)面和(220)面为主。MCD薄膜晶粒棱角分明,平均晶粒尺寸为2~3μm,NCD薄膜的表面更光滑,平均晶粒尺寸为100 nm。MCD和NCD薄膜测定区域的表面粗糙度值分别为0.4μm和0.24μm。在相同的切削条件下,无涂层刀具钻削30个孔后,刀具已经达到了报废标准,不能继续使用。两种金刚石涂层刀具各钻削50个孔后,MCD和NCD涂层刀具后刀面的最大磨损量分别为0.192 mm和0.093 mm,均没有超过磨钝标准VB=0.2 mm(后刀面磨损带宽度),其中NCD涂层刀具的耐磨性最好。结论 MCD和NCD薄膜,尤其是NCD薄膜,能够有效地提高硬质合金刀具的耐磨性,延长刀具的使用寿命。
The work aims to study microstructure and surface quality of microcrystalline diamond film(MCD film) and NCD film(nanocrystalline diamond film), as well as cutting performance of MCD and NCD coated spade drills made from MCD and NCD films in cutting carbon fiber reinforced plastics(CFRP). The method of HFCVD was used to deposit MCD and NCD films on the surface of cemented carbide spade drills. Scanning electron microscope(SEM) was applied to observe surface and cross-sectional morphology of as-deposited diamond films, white-light interferometry was adopted to measure surface roughness of the films, Raman spectroscopy was used to assess structural components of the films, X-ray diffractometer(XRD) was used to characterize crystal structure and crystal orientation of the films, and cutting experiment was performed to investigate cutting performance of uncoated tool as well as as-deposited MCD and NCD coated tool. The two kinds of films were evenly coated with diamond grains on the tool, both films were 8 μm thick, and crystal orientations were mainly in direction(111) and(220). The diamond grains of MCD film displayed pyramid structures with sharp edges and corners, the average grain size was about 2~3 μm. MCD film contained angular grains, and average grain size was 2~3 μm; and NCD film had a smoother surface, and average grain size was about 100 nm. Surface roughness value Ra of the MCD and NCD films in measured areas was 0.4 μm and 0.24 μm, respectively. Under the same cutting conditions, the uncoated tool reached rejection standardand could not be used any more after drilling 30 holes. After drilling 50 holes, MCD and NCD coated tools sustained the maximum abrasion loss of 0.192 mm and 0.093 mm, respectively on the flank, and none of them exceeded dullness standard VB=0.2 mm(width of flank wear land). The NCD coated tool exhibited the best wear resistance.The MCD and NCD films, especially NCD film, can effectively improve wear resistance of carbide cutting tools and extend service lives of the tools.
The work aims to study microstructure and surface quality of microcrystalline diamond film(MCD film) and NCD film(nanocrystalline diamond film), as well as cutting performance of MCD and NCD coated spade drills made from MCD and NCD films in cutting carbon fiber reinforced plastics(CFRP). The method of HFCVD was used to deposit MCD and NCD films on the surface of cemented carbide spade drills. Scanning electron microscope(SEM) was applied to observe surface and cross-sectional morphology of as-deposited diamond films, white-light interferometry was adopted to measure surface roughness of the films, Raman spectroscopy was used to assess structural components of the films, X-ray diffractometer(XRD) was used to characterize crystal structure and crystal orientation of the films, and cutting experiment was performed to investigate cutting performance of uncoated tool as well as as-deposited MCD and NCD coated tool. The two kinds of films were evenly coated with diamond grains on the tool, both films were 8 μm thick, and crystal orientations were mainly in direction(111) and(220). The diamond grains of MCD film displayed pyramid structures with sharp edges and corners, the average grain size was about 2~3 μm. MCD film contained angular grains, and average grain size was 2~3 μm; and NCD film had a smoother surface, and average grain size was about 100 nm. Surface roughness value Ra of the MCD and NCD films in measured areas was 0.4 μm and 0.24 μm, respectively. Under the same cutting conditions, the uncoated tool reached rejection standardand could not be used any more after drilling 30 holes. After drilling 50 holes, MCD and NCD coated tools sustained the maximum abrasion loss of 0.192 mm and 0.093 mm, respectively on the flank, and none of them exceeded dullness standard VB=0.2 mm(width of flank wear land). The NCD coated tool exhibited the best wear resistance.The MCD and NCD films, especially NCD film, can effectively improve wear resistance of carbide cutting tools and extend service lives of the tools.
引文
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[14]PFEIFFER R,KUZMANY H,KNOLL P,et al.Evidence for trans-polyacetylene in nano-crystalline diamond films[J].Diamond and related materials,2003,12(3-7):268-271.
[15]FU Yong-qing,YAN Bibo,LOH N L,et al.Characterization and tribological evaluation of MW-PACVD diamond coatings deposited on pure titanium[J].Materials science and engineering A,2000,282(1-2):38-48.
[16]FERRARI A C,ROBERTSON J.Origin of the 1150 cm-1raman mode in nanocrystalline diamond[J].Physical review B,2001,63(12):121405.
[17]SHEN Xiao-tian,WANG Xin-chang,SUN Fang-hong,et al.Sandblasting pretreatment for deposition of diamond films on WC-Co hard metal substrates[J].Diamond and related materials,2017,73:7-14.
[2]SHEN Bin,SUN Fang-hong.Deposition and friction properties of ultra-smooth composite diamond films on Co-cemented tungsten carbide substrates[J].Diamond and related materials,2009,18(2-3):238-243.
[3]WANG Xin-chang,SHEN Xiao-tian,SUN Fang-hong,et al.Mechanical properties and solid particle erosion of MCD films synthesized using different carbon sources by BE-HFCVD[J].International journal of refractory metals and hard materials,2016,54:370-377.
[4]WANG Xin-chang,ZHAO Tian-qi,SUN Fang-hong,et al.Comparisons of HFCVD diamond nucleation and growth using different carbon sources[J].Diamond and related materials,2015,54:26-33.
[5]ZHANG Jian-guo,WANG Xin-chang,SHEN Bin,et al.Effect of boron and silicon doping on improving the cutting performance of CVD diamond coated cutting tools in machining CFRP[J].International journal of refractory metals and hard materials,2013,41:285-292.
[6]LIN S C,CHEN I K.Drilling carbon fiber-reinforced composite material at high speed[J].Wear,1996,194(1-2):156-162.
[7]LLIESCU D,GEHIN D,GUTIERREZ M E,et al.Modeling and tool wear in drilling of CFRP[J].International journal of machine tools and manufacture,2010,50(2):204-213.
[8]GAUGEL S,SRIPATHY P,HAEGER A,et al.A comparative study on tool wear and laminate damage in drilling of carbon-fiber reinforced polymers(CFRP)[J].Composite structures,2016,155:173-183.
[9]DUMPALA R,CHANDRAN M,MADHAVAN S,et al.High wear performance of the dual-layer graded composite diamond coated cutting tools[J].International journal of refractory metals and hard materials,2015,48:24-30.
[10]CUI Yu-xiao,WANG Wei-song,SHEN Bin,et al.A study of CVD diamond deposition on cemented carbide ball-end milling tools with high cobalt content using amorphous ceramic interlayers[J].Diamond and related materials,2015,59:21-29.
[11]沈彬,孙方宏,张志明,等.CVD金刚石薄膜涂层整体式刀具的制备与应用[J].金刚石与磨料磨具工程,2011(1):1-5.SHEN Bin,SUN Fang-hong,ZHANG Zhi-ming,et al.Fabrication and application of CVD diamond coated cutting tools[J].Diamondand abrasives engineering,2011(1):1-5.
[12]WANG Tao,XIANG Li,SHI Wei,et al.Deposition of diamond/β-Si C/Cobalt silicide composite interlayers to improve adhesion of diamond coating on WC-Co substrates by DC-plasma assisted HFCVD[J].Surface and coatings technology,2011,205(8-9):3027-3034.
[13]Al MEIDA F A,AMARAL M,OLIVEIRA F J,et al.Nano to micrometric HFCVD diamond adhesion strength to Si3N4[J].Vacuum,2007,81(11-12):1443-1447.
[14]PFEIFFER R,KUZMANY H,KNOLL P,et al.Evidence for trans-polyacetylene in nano-crystalline diamond films[J].Diamond and related materials,2003,12(3-7):268-271.
[15]FU Yong-qing,YAN Bibo,LOH N L,et al.Characterization and tribological evaluation of MW-PACVD diamond coatings deposited on pure titanium[J].Materials science and engineering A,2000,282(1-2):38-48.
[16]FERRARI A C,ROBERTSON J.Origin of the 1150 cm-1raman mode in nanocrystalline diamond[J].Physical review B,2001,63(12):121405.
[17]SHEN Xiao-tian,WANG Xin-chang,SUN Fang-hong,et al.Sandblasting pretreatment for deposition of diamond films on WC-Co hard metal substrates[J].Diamond and related materials,2017,73:7-14.