机械毕业设计英文外文翻译271金刚石涂层刀具的涂层厚度的影响.docx

附录外文文献翻译 金刚石涂层刀具的涂层厚度的影响 作者： F. Qin, Y.K. Chou,D. Nolen and R.G. Thompson 发表日期： 2009 摘要： 化学气相沉积法（ CVD），金刚石薄膜的发现，作为涂层刀具的应用。即使传统的金刚石涂层的使用似乎是公认的切削，为不同的加工操作选择适当的涂层厚度没有经常研究。涂层厚度影响涂层刀具在不同的角度，可能相互影响，在复杂的方式，在机械加工工具金刚石工具的性能特点。 在这项研究中，在沉积层厚度对残余应力，特别是围绕一个前沿，对涂层的破坏模式进行了数值研究。另一方面，刀具表面光滑涂层厚度的影响以及尖端的半径进行了实验研究。 此外，铝基复合材料加工用金刚石涂层刀具涂层厚度变化进行了评估对切削力的影响，零件表面光洁度和刀具磨损。 结果归纳如下 : （一）增加涂层厚度，涂层残余应力，基体界面。（ 2）在另一方面，增加涂层厚度一般会增加涂层耐开裂和脱层。（ 3）厚涂层将在更大的优势半 径的结果，但是，对切削力的影响程度还取决于加工条件。（ 4）的厚度范围内进行测试，对金刚石涂层刀具寿命与因分层延迟涂层厚度的增加。 关键词：涂层厚度、金刚石涂层、有限元、加工、刀具磨损 1、介绍 采用化学气相沉积金刚石涂层生产法（ CVD）技术已被越来越多地探讨了刀具的应用。金刚石涂层刀具在不同的加工应用的巨大潜力和优势，如切削钻头几何形状复杂的工具捏造。 轻质高强度部件的增加也导致惯例，在金刚石涂层工具的重大利益。热丝化 学气相沉积金刚石涂层的是，厚度为 50 微米，对包括钴硬质合金（碳化钨钴） 1碳化钨各种材料沉积金刚石薄膜被普遍进程之一。 也有不同的化学气相沉积技术，如微波等离子体辅助 CVD，发展到提高沉积过程以及电影的质量了。 然而，尽管上级摩擦学和力学性能，金刚石涂层刀具的实际应用仍然有限。 涂层厚度是最重要的属性之一，涂层系统的性 能。涂层的摩擦学性能厚度的影响已被广泛研究。 一般来说，加厚涂层具有较好划伤 /耐磨性比瘦的，因为它们更承载能力的表现。不过，也有报道说，索赔。 例如，多纳等。 发现，即类金刚石涂层（类金刚石）厚度在 0.7-3.5 微米范围内的，不影响耐磨性的 DLC - Ti6Al4V 合金 3。对于刀具的应用，然而，涂层厚度可能有其影响可能是因为周围的尖端更复杂的作用增强。 涂层厚度对金刚石涂层刀具的影响是不是经常报道。神田等人。 进行使用金刚石涂层刀具切削试验。 撰文声称，增加薄膜的厚度一般是有利的刀具寿命。 然而，在较厚的薄膜将导致在 横向断裂强度，大大影响了在高速或中断加工性能降低。此外，更高的切削力，观察的工具，金刚石涂层厚度的增加，由于增加了尖端半径。 夸德里尼等。研究金刚石涂层对牙科应用小造纸厂。 作者不同的测试涂层厚度，并指出，导致高厚涂层，由于涂层表面粗糙度增加和扩大优势四舍五入切削力。这种影响可能会导致失败的铣削刀具陶瓷材料。提交人进一步表示，在薄涂层聚合物基复合材料 最佳的切割效工具。 此外，托雷斯等人。 研究了金刚石涂层微观两个层次立铣刀的涂层厚度。作者还指出，薄涂层，可进一步降低切割这是由于在摩擦力和粘附力下降。 不 同的涂料涂装材料工具厚度影响也进行了研究。 单层系统，最佳涂层厚度可能存在的加工性能。例如，塔夫等。 报告说，一对 TiN 涂层的 PVD 技术的最佳厚度为特定的加工条件存在 8。根据测试结果，为从 1.75 至 7.5 微米 TiN 涂层， 3.5 微米展览的最佳转弯性能厚度。 在另一项研究中，马立克等。 还有人建议，有一对的 TiN 涂层高速钢刀具加工时的最佳厚度易切削钢。但是，对于多层涂层系统，没有这样一个最佳的涂层厚度为加工性能存在。 这项研究的目的是为了实验研究金刚石涂层厚度对涂层刀具加工性能 - 刀具磨损和切削力。金刚石涂层刀具的制备，微波等离子体辅助 CVD，不同涂层厚度。 钻石是在形态和边缘半径审查白光干涉涂层刀具。 然后，由钻石加工铝评估干基复合涂层工具。此外，沉积热残余应力和涂层失效，影响了金刚石涂层刀具性能的关键负荷的解析研究。 2、实验研究 金刚石涂层的基体实验中使用的，方形刀片（ SPG422），是细颗粒碳化钨 6重量。钴。边缘半径和切削刀片涂层表面纹理之前，是衡量一个白光干涉仪，由 Veeco 公司计量 NT1100。 在此之前的沉积，化学蚀刻上插入进行治疗，以消除和粗糙的表面钴基体表面 。此外，所有工具插入了超声波振动在金刚石 /水泥浆，以增加成核密度。对于涂层工艺，沉积金刚石薄膜用高功率微波等离子体辅助化学气相沉积过程。阿以 4.4-7.3的甲烷 /氢气比例在氢气，甲烷， 750-1000 sccm 的气体混合物，被用来作为原料气体。氮气， 2.75-5.5 sccm 的，是获得纳米结构插入防止柱状增长。 压力约 30-55 托和衬底温度约为 685-830 摄氏度 一个低沉积率 4.5-5.0 千瓦的功率得到了一个薄涂层 ;一个更大的推进 8.0-8.5 千瓦的高功率沉积速率得到厚涂层，通过改变沉积时间 2 厚度。 涂层刀片的进一步检查的干涉。 计算机数控车床，哈丁眼镜蛇 42 条，被用来进行加工实验，外径车削，以评估金刚石工具磨损涂层刀具。 随着使用，金刚石涂层刀具刀片刀柄形成了 0 前角， 11 后角，和 75 导角。 工件都是 A359/SiC-20p 复合材料制成圆棒。使用的加工条件分别为 4 米 /秒的切割速度， 0.15 毫米 /转速饲料，切深 1 毫米，无冷却剂的应用。 对加工参数的选择是基于以前的经验。 对于每个涂层厚度，两个试验重复。 在加工测试，切割刀片进行定期检查用光学显微镜测量侧面磨损土地面积。 废旧工具测试后还审议通过 扫描电子显微镜（ SEM）。此外，切削加工过程中进行了监测力量使用奇石乐测力计。 5、 结论 在这项研究中，对金刚石涂层刀具的涂层厚度的影响从不同的角度进行了研究。沉积残余应力的工具由于热不匹配是由有限元模拟和接口上的涂层厚度的影响，强调了量化研究。此外，钻石压痕模拟碳化钨涂层与基体的粘结带模拟接口被用于分析涂层系统故障。此外，不同厚度的金刚石涂层刀具的制备和表面形貌实验，边四舍五入调查，以及在机械加工刀具磨损和切削力。主要结果归纳如下。 （ 1）增加涂层厚度大大增加了接口的残余应力，虽然变化不大散装表面应力。 （ 2）厚涂层，涂层失效的临界载荷随涂层厚度的减小。不过，这种趋势是相反的薄涂层，对此径向开裂的涂层的失效模式。 此外，加厚涂层有更大的脱层阻力。 （ 3）此外，增加涂层厚度的增加边缘半径。但是，在涂层厚度范围内研究， 4-29微米，与大饲料中使用，切削力受到影响轻微。 （ 4）尽管有更大的界面残余应力，提高金刚石涂层厚度，为研究范围，似乎增加涂料分层延迟刀具寿命。 这项研究是由美国国家科学基金会的支持，批准号： CMMI的 0728228。 提供了一些分析援助。 附录外文文献原文 Coating thickness effects on diamond coated cutting tools F. Qin, Y.K. Chou,D. Nolen and R.G. Thompson Available online 12 June 2009. Abstract： Chemical vapor deposition (CVD)-grown diamond films have found applications as a hard coating for cutting tools. Even though the use of conventional diamond coatings seems to be accepted in the cutting tool industry, selections of proper coating thickness for different machining operations have not been often studied. Coating thickness affects the characteristics of diamond coated cutting tools in different perspectives that may mutually impact the tool performance in machining in a complex way. In this study, coating thickness effects on the deposition residual stress es, particularly around a cutting edge, and on coating failure modes were numerically investigated. On the other hand, coating thickness effects on tool surface smoothness and cutting edge radii were experimentally investigated. In addition, machining Al matrix composites using diamond coated tools with varied coating thicknesses was conducted to evaluate the effects on cutting forces, part surface finish and tool wear. The results are summarized as follows. Increasing coating thickness will increase the residual stresses at the coatingsubstrate interface. On the other hand, increasing coating thickness will generally increase the resistance of coating cracking and delamination. Thicker coatings will result in larger edge radii; however, the extent of the effect on cutting forces also depends upon the machining condition. For the thickness range tested, the life of diamond coated tools increases with the coating thickness because of delay of delaminations. Keywords: Coating thickness; Diamond coating; Finite element; Machining; Tool wear 1. Introduction Diamond coatings produced by chemical vapor deposition (CVD) technologies have been increasingly explored for cutting tool applications. Diamond coated tools have great potential in various machining applications and an advantage in fabrications of cutting tools with complex geometry such as drills. Increased usages of lightweight high-strength components have also resulted in significant interests in diamond coating tools. Hot-filament CVD is one of common processes of diamond coatings and diamond films as thick as 50 m have been deposited on various materials including cobalt-cemented tungsten carbide (WC-Co) . There have also been different CVD technologies, e.g., microwave plasma assisted CVD , developed to enhance the deposition process as well as the film quality too. However, despite the superior tribological and mechanical properties, the practical applications of diamond coated tools are still limited. Coating thickness is one of the most important attributes to the coating system performance. Coating thickness effects on tribological performance have been widely studied. In general, thicker coatings exhibited better scratch/wear resistance performance than thinner ones due to their better load-carrying capacity. However, there are also reports that claim otherwise and . For example, Dorner et al. discovered, that the thickness of diamond-like-coating (DLC), in a range of 0.73.5 m, does not influence the wear resistance of the DLCTi6Al4V . For cutting tool applications, however, coating thickness may have a more complicated role since its effects may be augmented around the cutting edge. Coating thickness effects on diamond coated tools are not frequently reported. Kanda et al. conducted cutting tests using diamond-coated tooling . The author claimed that the increased film thickness is generally favorable to tool life. However, thicker films will result in the decrease in the transverse rupture strength that greatly impacts the performance in high speed or interrupted machining. In addition, higher cutting forces were observed for the tools with increased diamond coating thickness due to the increased cutting edge radius. Quadrini et al. studied diamond coated small mills for dental applications . The authors tested different coating thickness and noted that thick coatings induce high cutting forces due to increased coating surface roughness and enlarged edge rounding. Such effects may contribute to the tool failure in milling ceramic materials. The authors further indicated tools with thin coatings results in optimal cutting of polymer matrix composite . Further, Torres et al. studied diamond coated micro-endmills with two levels of coating thickness . The authors also indicated that the thinner coating can further reduce cutting forces which are attributed to the decrease in the frictional force and adhesion. Coating thickness effects of different coating-material tools have also been studied. For single layer systems, an optimal coating thickness may exist for machining performance. For example, Tuffy et al. reported that an optimal coating thickness of TiN by PVD technology exists for specific machining conditions . Based on testing results, for a range from 1.75 to 7.5 m TiN coating, thickness of 3.5 m exhibit the best turning performance. In a separate study, Malik et al. also suggested that there is an optimal thickness of TiN coating on HSS cutting tools when machining free cutting steels . However, for multilayer coating systems, no such an optimum coating thickness exists for machining performance . The objective of this study was to experimentally investigate coating thickness effects of diamond coated tools on machining performance tool wear and cutting forces. Diamond coated tools were fabricated, by microwave plasma assisted CVD, with different coating thicknesses. The diamond coated tools were examined in morphology and edge radii by white-light interferometry. The diamond coated tools were then evaluated by machining aluminum matrix composite in dry. In addition, deposition thermal residual stresses and critical load for coating failures that affect the performance of diamond coated tools were analytically examined. 2. Experimental investigation The substrates used for diamond coating experiments, square-shaped inserts (SPG422), were fine-grain WC with 6 wt.% cobalt. The edge radius and surface textures of cutting inserts prior to coating was measured by a white-light interferometer, NT1100 from Veeco Metrology. Prior to the deposition, chemical etching treatment was conducted on inserts to remove the surface cobalt and roughen substrate surface. Moreover, all tool inserts were ultrasonically vibrated in diamond/water slurry to increase the nucleation density. For the coating process, diamond films were deposited using a high-power microwave plasma-assisted CVD process. A gas mixture of methane in hydrogen, 7501000 sccm with 4.47.3% of methane/hydrogen ratio, was used as the feedstock gas. Nitrogen gas, 2.755.5 sccm, was inserted to obtain nanostructures by preventing columnar growth. The pressure was about 3055 Torr and the substrate temperature was about 685830 C. A forward power of 4.55.0 kW with a low deposition rate obtained a thin coating; a greater forward power of 8.08.5 kW with a high deposition rate obtained thick coatings, two thicknesses by varying deposition time. The coated inserts were further inspected by the interferometer. A computer numerical control lathe, Hardinge Cobra 42, was used to perform machining experiments, outer diameter turning, to evaluate the tool wear of diamond coated tools. With the tool holder used, the diamond coated cutting inserts formed a 0 rake angle, 11 relief angle, and 75 lead angle. The workpieces were round bars made of A359/SiC-20p composite. The machining conditions used were 4 m/s cutting speed, 0.15 mm/rev feed, 1 mm depth of cut and no coolant was applied. The selection of machining parameters was based upon previous experiences. For each coating thickness, two tests were repeated. During machining testing, the cutting inserts were periodically inspected by optical microscopy to measure the flank wear-land size. Worn tools after testing were also examined by scanning electron microscopy (SEM). In addition, cutting forces were monitored during machining using a Kistler dynamometer. 5. Conclusions In this study, the coating thickness effects on diamond coated cutting tools were studied from different perspectives. Deposition residual stresses in the tool due to thermal mismatch were investigated by FE simulations and coating thickness effects on the interface stresses were quantified. In addition, indentation simulations of a diamond coated WC substrate with the interface modeled