Development of diamond coated tool and its performance in machining Al-11% Si alloy

An attempt has been made to deposit CVD diamond coating on conventional carbide tool using hot filament CVD process. ISO grade K10 turning inserts with SPGN 120308 geometry were used to deposit diamond coating. This diamond coating well covering the rake surface, cutting edges and flank surfaces could be successfully deposited. The coatings were characterized by SEM, XRD and Raman spectroscopy for coating quality, morphology etc. Performance of diamond coated tool relative to that of uncoated carbide tool was evaluated in turning Al-11% Si alloy under dry environment. The diamond coated tool outperformed the uncoated carbide tool which severely suffered from sizeable built-up edge formation leading not only to escalation of cutting forces but also poorer surface finish. In contrast, the diamond coated tool, owing to chemical inertness of diamond coating towards the work material, did not show any trace of edge built-up even in dry environment and could maintain low level of cutting forces and remarkably improved surface finish. It has been further revealed that success of the diamond coated tool depends primarily on adhesion of the diamond coating with the carbide substrate and this is strongly influenced by the pre-treatment of the carbide substrate surface before coating.