Diamond coated tools are made using a process known as Hot Filament Deposition, which is a type of Chemical Vapor Deposition (CVD) technology. In this process, an array of superheated tungsten wires is used to activate hydrogen and a carbon-containing gas, usually methane.
The diamond coating can be applied to the cutting tool in two different ways. One method involves bonding micron-sized diamond grains onto a metal matrix, usually cobalt, which is then sintered onto the tool. This is known as polycrystalline diamond (PCD) and is commonly used in mining and cutting applications.
The other method is to grow a thin diamond film directly onto the tool's base body, which is typically made of cemented carbide. This process allows for more complex shapes, smaller angles, and dimensions that are not possible with PCD. The diamond film can be optimized for different applications by growing it thin and smooth for sharp tool edges or thicker for increased abrasion resistance.
The diamond grains used in the coating can be either monocrystals or polycrystals. Monocrystals can be natural or created through High-Pressure High-Temperature (HPHT) synthesis, while polycrystals are made through detonation synthesis. The diamond grains are bonded to the tool base body using polymers (resin), ceramics (vitrified), or metals. The grain size can be adjusted by crushing larger grains.
One of the advantages of the CVD diamond-coating process is the ability to grow a wide range of surface structures and optimize the film for specific applications. For example, growing a faceted surface has been shown to reduce cutting forces and increase tool lifetime.
Diamond coated tools can be used for various cutting applications, and most tools with a diameter between 0.008" (0.20mm) and 0.500" (12.70mm) can be diamond coated. Larger diameters can also be coated, but it is usually more cost-effective to use insert tooling for these sizes. Many tool companies stock diamond-coated cutting tools or can manufacture them for customers.
Diamond-coated tools have unique physical properties that make them ideal for cutting applications. Diamond is the hardest known material and highly abrasion resistant. It also has extremely high thermal conductivity, which helps remove damaging heat from the cutting edge. The low coefficient of friction of diamond aids in material flow up the flutes of the coated tools. These properties allow diamond tools to run at high speeds without damage and at cooler temperatures compared to other tool materials, reducing damage to heat-sensitive workpiece materials.
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