金刚石涂层刀具的核心性能优势

金刚石涂层刀具凭借金刚石材料的卓越特性及先进涂层技术，展现出多方面的性能优势。其涂层硬度高，抗氧化性能好，切削性能优于TiN涂层，用于加工航天合金材料时的刀具寿命可提高1～4倍。用金刚石刀具切削硅铝合金等硬质材料时，具有加工精度高，切削寿命长，切削力小，加工效率高等优点。金刚石是自然界中硬度最高的物质，兼具高耐磨性、低摩擦系数与较高的化学惰性，制成的刀具可以精加工石墨、高硅铝合金等难切削材料。

金刚石涂层刀具性能的影响因素

·         涂层制备工艺：不同的化学气相沉积（CVD）法对性能影响不同。热丝CVD（HFCVD）法制备成本相对较低，可以实现金刚石大面积均匀沉积，能在硬质合金刀具等多种材料上镀金刚石膜，但制备出的金刚石膜品质稍差于微波等离子体CVD（MPCVD）法和直流电弧等离子体喷射CVD（DAPCVD）法。等离子辅助化学气相沉积（PCVD）可使沉积温度降低到200～500℃。

·         沉积参数：通过优化沉积参数，包括沉积功率、衬底温度、沉积气压及碳源种类，可以提高金刚石涂层的形核密度，并降低涂层的生长残余应力，从而增强涂层与刀具的结合力。

·         刀具基体与涂层结合：在全涂型和前涂型刀具上，涂层起硬隔膜作用，表现为减少了刀具的粘蚀磨损，降低了扩散磨损和热电磨损，由于降低了切削力和切削温度，因而可降低刀具的弹塑性变形。一般说来，涂层刀具当后角偏大时会得到更满意的性能。

·         加工材料：同样的一把涂层刀具，随着加工材料的不同，其切削寿命的差别亦很大。

金刚石涂层刀具的应用体现的性能

金刚石涂层刀具应用于航空航天、新能源、电子电路、精密加工领域，可用于石墨模具、石墨极板、陶瓷牙齿、5G线路板、铝合金、碳纤维等的加工制造。主要用于高速精密加工、数控加工、高硅铝合金、石墨及其它有色金属材料加工刀具及高耐磨材料和高级复合材料的加工刀具领域。这些应用场景充分体现了其在加工难切削材料时的高效性、高精度和高耐磨性等优良性能。例如，在加工高强度铝合金和贵重金属方面有良好的应用前景。当加工各种难加工材料时，有时用不涂层刀具根本不能加工，即使勉强能用，其寿命也是极低，而金刚石涂层刀具则能较好地满足加工需求。

Ba Dao Sharing - Performance of Diamond-Coated Tools

The core performance advantages of diamond-coated cutting tools

Diamond-coated cutting tools, thanks to the outstanding properties of diamond materials and advanced coating technology, demonstrate multiple performance advantages. Its coating has high hardness, good oxidation resistance and superior cutting performance compared to TiN coating. When used for processing aerospace alloy materials, the tool life can be increased by 1 to 4 times. When cutting hard materials such as silicon and aluminum alloys with diamond tools, they have the advantages of high processing accuracy, long cutting life, low cutting force and high processing efficiency. Diamond is the hardest substance in nature, featuring high wear resistance, low friction coefficient and high chemical inertness. The cutting tools made from it can precisely process difficult-to-cut materials such as graphite and high-silicon aluminum alloys.

Influencing factors of diamond-coated cutting tool performance

· Coating preparation process: Different chemical vapor deposition (CVD) methods have different effects on performance. The hot wire CVD (HFCVD) method has a relatively low preparation cost, can achieve large-area uniform deposition of diamond, and can gold diamond films on various materials such as cemented carbide tools. However, the quality of the prepared diamond films is slightly inferior to that of the microwave plasma CVD (MPCVD) method and the direct current arc plasma jet CVD (DAPCVD) method. Plasma-assisted chemical vapor deposition (PCVD) can reduce the deposition temperature to 200-500℃.

· Deposition parameters: By optimizing the deposition parameters, including deposition power, substrate temperature, deposition air pressure and carbon source type, the nucleation density of the diamond coating can be increased and the growth residual stress of the coating can be reduced, thereby enhancing the adhesion between the coating and the tool.

The combination of tool substrate and coating: On fully coated and pre-coated tools, the coating acts as a hard separator, which is manifested as reducing the adhesive wear of the tool, lowering diffusion wear and thermoelectric wear. Due to the reduction of cutting force and cutting temperature, it can also reduce the elastic-plastic deformation of the tool. Generally speaking, coated cutting tools will achieve more satisfactory performance when the relief Angle is relatively large.

· Processing material: For the same coated cutting tool, the cutting life varies greatly depending on the processing material.

The performance demonstrated by the application of diamond-coated cutting tools

Diamond-coated cutting tools are applied in aerospace, new energy, electronic circuits, and precision machining fields. They can be used in the processing and manufacturing of graphite molds, graphite plates, ceramic teeth, 5G circuit boards, aluminum alloys, carbon fibers, etc. It is mainly used in the fields of high-speed precision processing, CNC processing, high-silicon aluminum alloy, graphite and other non-ferrous metal material processing tools, as well as high-wear-resistant materials and advanced composite materials processing tools. These application scenarios fully demonstrate its excellent performance such as high efficiency, high precision and high wear resistance when processing difficult-to-cut materials. For instance, it has a promising application prospect in processing high-strength aluminum alloys and precious metals. When processing various difficult-to-machine materials, sometimes uncoated tools cannot be used at all. Even if they can be used with difficulty, their service life is extremely low. However, diamond-coated tools can better meet the processing requirements.

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