Conventional tungsten carbide (WC–Co) cutting tools mostly fail to machine the mild-steel metallic alloy properly, under heavy turning parameters. The present industrial applications demand super hard coatings for better performance and durability of cutting tools. The diamond-coated WC–Co cutting tool is the best option for machining of mild-steel alloy under high cutting speed and load conditions. Generally, the WC–Co tool bits were coated by synthetic diamond using hot filament chemical vapor deposition technique. However, using single layers of nanocrystalline diamond and microcrystalline diamond coatings on WC–Co cutting tools is not sufficient to enhance their mechanical and tribological properties according to the present industrial requirement. In this work, the dual-layer diamond coating system was deposited on chemically etched WC–Co cutting inserts by adjoining the layers of both nanocrystalline diamond and microcrystalline diamond coatings with the coating architecture of WC–Co/microcrystalline diamond/nanocrystalline diamond, enhancing the mechanical properties and machining performance of WC–Co cutting tools. In this regard, a comparison has been documented between dual-layer diamond-coated and conventional WC–Co cutting tools on the dry machining of mild-steel alloy using computer numerical control machine to study their cutting performance. Therefore, the use of dual-layer diamond coating system on WC–Co cutting tools with good integrity and with top-layer nanocrystallinity was expected to give the advantages of both nanocrystalline diamond and microcrystalline diamond coatings and enhance the tool life.
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture – SAGE
Published: Jun 1, 2018
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