Essay about Diamond Coated Machine Tooling

Diamonds is the hardest known natural material in the world. The hardness of this mineral as well as their thermal conductivity is the main reason it has found many industrial uses. A total of 80% of mined diamond are unsuitable for use as gemstones and are used for industrial purposes.

Diamond has a giant molecular structure. Each carbon atom is covalently bonded to four other carbon atoms. Since covalent bonds are so strong, a great amount of energy is required to seperate the atoms in a diamond,

Diamond is one of the most commonly known carbon allotropes. One of the properties that it is known for is how hard it is. It is a natural material with the highest reading on the Vickers and Mohs scale. Diamond also has a very high thermal conductivity. The reason it has these properties is mainly due how the atoms are structured. This structure is a varied version of a face-centered cubic and is called a diamond lattice. These two properties are what diamonds are used for in major industrial application. Since diamonds are always decaying to graphite, the properties vary depending on the perfection of the crystal lattice and its orientation. Diamonds have other less important properties when it comes to being used in industry. The difference in colours of diamonds, depends on impurities in the crystal lattice structure that alters the wavelength of light that is absorbed. They also have, luster, fluorescence, optical absorption, electrical properties, thermal conductivity, and thermal stability. Diamonds are known for being used as jewelry, however the majority of mined diamonds are used for industrial purposes. Since diamonds are super hard, they can be put into drill bits in order to cut other really hard materials. They can cut other softer gemstones into a symmetrical or more beautiful shape so they can be sold. Diamonds are used to conduct heat, they are used to coat microchips to conduct electricity, and they are used in many

Alumina (〖Al〗_2 O_3) and Silicon Nitride (〖Si〗_3 N_4) are most commonly found in a ceramic cutting material. Their attributes differ for their own specific purpose, but they all have the same core characteristics. They all demonstrate elevated hardness, strength, and thermal conductivity. Thermal conductivity is one of the main advantages in using ceramics over other materials. Ceramics can withstand temperatures over 4000℉ in its operation, while Carbide can only reach 1600℉. Cutting materials at this heat allows for the material being cut to be softened, allowing for a smoother, easier pass. These high temperatures are unattainable for carbide tools because they exceed its melting point. Ideal-machining temperatures (e.g., 2200°F for nickel alloys) can be accommodated by

Lawal et al. [16] has done an evaluation on the performance of vegetable oil in turning process in comparison to mineral oil. The investigation found that the vegetable oil surpass conventional oil-in-water performance in turning process. Likewise, Babur et al. [17] have conclude that vegetable oil are effective in producing better surface quality and tool wear than synthetic cutting fluids during turning process. Nevertheless, improvement on the performance of vegetable oil can be done by utilising powder particles such as MoS2, graphite, boric acid, etc. Improvement can be seen from using powder particle aided lubricant in terms of surface finish, coefficient of friction, wear and cutting force [18]. This is because powder particle has lattice layered structure (Fig. 1), relatively high load carrying capacity and low steady state coefficient of friction [19]. Moreover, powder particle such as boric acid are environmentally friendly and do not pose threat to operational workers according to the Environmental Protection Agency, which is desirable in creating a greener lubrication in machining application

The axes comprise the vast majority of Gülpınar polished cutting edge stone tool assemblage. They are generally pecked or ground with a transverse cutting edges, elongated triangular in section with tapering, rounded butt; sharpened the symmetrical blade and elliptical-sub rectangular in cross section. Also, they have polished and flat surfaces and no visible wear traces on blades except few specimens. Some specimens had extensive wear traces, which are may result of felling trees, carpentry related tasks or cutting, chopping and butchery related tasks. Polished axes have more advantages than flaked axes because of their polished cutting surfaces. The symmetrical edges and smooth surfaces penetrate deeper on wood during cutting activities (Bordaz

Abrasive Jet Machining (AJM) is the removal of material from a work piece by the application of a high speed stream of abrasive particles carried in gas medium from a nozzle. The AJM process is different from conventional sand blasting by the way that the abrasive is much finer and the process parameters and cutting action are both carefully regulated. The process is used chiefly to cut intricate shapes in hard and brittle materials which are sensitive to heat and have a tendency to chip easily. The process is also used for drilling, de-burring and cleaning operations. AJM is fundamentally free from chatter and vibration problems due to absence of physical tool. The cutting action is cool because the carrier gas itself serves as a coolant and takes away the heat.

Dean and Triana’s invention is running into trouble when it is used continuously for long periods of time because the cams are too soft, resulting in wear and misalignment in the invention. They already have all of the cams, so switching materials is not an option, so we must find a way to harden the surface of the cams to reduce wear. The cams are made of 1020 steel, which has a hardness of 111 HB, and only has 0.20% carbon, classifying it as a low carbon steel. For this reason we recommend that carburization be utilized to increase the carbon composition at the surface, and thus increase the surface hardness. This occurs because the presence of carbon interstitially diffused

Barber et al., 2005 discussed the development of sub-surface damage during high energy solid particle erosion of a thermally sprayed WC–Co–Cr coating. The samples tested were 50 mm×50 mm×10 mm carbon steel plates with a nominal 300 µm thick WC–Co–Cr coating. Each sample was lapped using 14 µm diamond lap- ping paste which ensured consistency in surface finish to an Ra of 0.05 µm. The test conditions were: sand velocity 148 m/s, sand feed rate of 6 g/min to give a flux of 0.5 kg/m2/s, test duration 10, 20 and 30 min. The erosion wear performance of a thermally sprayed hard coating has been found to be inferior to that of sintered bulk material of the same composition. The number and length of cracks found, both parallel and transverse to the substrate boundary, in eroded samples of thermally sprayed WC–Co–Cr material. The initiation sites of these cracks are also studied and the importance of voids and other microstructural features (i.e. cobalt lakes, splat boundaries, interfacial inclusions) in the coating as initiation sites is highlighted. The cracks appear in near-surface layers that are likely regions of localised plasticity in the matrix and could result from a mixed mode of

Milling is a vital process used in the industry to make and assembling the components. The extensive and expensive experimental work is necessary to determine the optimal of machining process parameters for obtaining the desired machined quality. In this regard, the present work is focused on the relationship between the input process parameters and machined surface integrity for minimizing the machined damage. Moreover, the paper presents the comparative analysis and performance of two different mill tools such as a specially designed carbide tipped tool and a solid carbide tool. Subsequently, comparing the evaluation of two tools was illustrated by plotting origin graphs. Finally, experimental results were thoroughly analyzed by SEM to investigate the cutting characteristics of machined laminates.

Ezugwu and Wang (1997) presented a review on the main problems associated with titanium machining, including tool wear and the mechanism responsible for tool failure. They suggest that uncoated carbides (WC/Co) cutting tools are better than most coated cutting tools for machining a titanium alloy. The high chemical reactivity of titanium causes welding of work-piece material on the cutting tool during machining, leading to chipping and premature tool failure. The prominent failure modes in titanium machining were: notching, flank wear, crater wear, chipping, and catastrophic failure. Different tool materials have different response to different wear mechanism. Crater wear is closely related to the chemical composition of the cutting tool. The conclusions presented by this researcher, they suggest that dissolution-diffusion wear dominates on the rake and flank face for uncoated cemented carbides used for the turning of titanium alloys. At very high cutting speeds and temperatures, the conclusion is that plastic deformation and development of cracks due to thermal shock will be the dominating wear mechanisms. Change of feed rate, depth of cut or cutting speed give changes in the wear rates. They also suggest that cutting fluids have to be used during titanium machining to minimize high stresses and temperatures. The cutting fluid has to work both as coolant and lubricating agent to lower the cutting forces and avoid chip welding, which is a phenomenon often experienced during

For machining sintered carbides should use chromium nickel steel and silver tools for the application.

Around the year 2000 more became known about the attractive properties of diamond-like carbons and Gillette, the market leader of razor blades, saw its potential. Gillette patented the use of particular DLC’s applied to the cutting edges of the razors. By that it improved the hardness, shave ability and corrosion

Technologies involved in machining operations have advanced greatly in the recent decades and machines have experienced significant changes such as the incorporation of numerical control. Every year it is possible to observe in fairs, conferences and of course in the market economy, how production capabilities have increased thanks to the development of new concepts, devices, materials, tools, coatings, structures, etc. Accuracy, flexibility and productivity are enhanced constantly with innovative solutions to achieve market demands or even raise them to higher levels. In the end, all these improvements are possible thanks to the generation of knowledge.

Grinding is a metal cutting operation performed by means of abrasive particles rigidly mounted on a rotating wheel. Each of the abrasive particles act as a single point cutting tool and grinding wheel acts as a multipoint cutting tool. The grinding operation is used to finish the work pieces with extremely high quality of surface finish and accuracy of shape and dimension. Grinding is one of the widely accepted finishing operations because it removes material in very small size of chips 0.25 to 0.50 mm. It provides accuracy of the order of 0.000025 mm. grinding of very hard material is also possible.