SBIR Phase II: Improving the Adhesion of Nanocarystalline Diamond Films to Tungsten Carbide Micro End Mills

该小型企业创新研究（SBIR）第二阶段项目旨在开发一种新颖的，商业上可行的混合系统，以提高纳米金刚石（NCD）涂层对碳化钨（WC）刀具的粘附力。一个新的混合动力系统将组装，测试和优化。将进行研究，以扩大工艺规模，达到一次涂覆3,000多件刀具的能力。进一步的研究将通过对这些金刚石涂层微型端米尔斯的实验室和工业切削性能测试进行。测试变量包括刀具尺寸、刀具几何形状、加工参数（切削速度、轴向切削深度、进给速度）、工件材料和环境条件。工业反馈将用于确保涂层优化，以满足真实的用户的需求。该项目的更广泛/商业影响将是显着提高微型工具性能的潜力。 该行业的一个重要领域目前受到微型立铣刀性能差的限制。提高模具性能不仅可以降低该领域的资本机器成本，还有助于实现受当前制造能力限制的现有尖端技术的小型化。NCD工具涂层最有前途的社会效益将在医疗保健行业实现，因为金刚石涂层对于下一代生物传感器和生物医学设备的开发至关重要。这将大大提高生物样本检测的质量，大幅降低相关成本，减轻个人和国家的医疗保健费用负担。

This Small Business Innovation Research (SBIR) Phase II project aims to develop a novel, commercially-viable, hybrid system that improves the adhesion of nanocrsytalline diamond (NCD) coatings to tungsten carbide (WC) cutting tools. A new hybrid system will be assembled, tested, and optimized. Research will be conducted to scale up the process to reach the capability of coating more than 3,000 cutting tools at one time. Further research will be conducted through laboratory and industrial machinability testing on these diamond-coated micro end mills. Testing variables include tool size, tool geometry, machining parameters (cutting speed, axial depth of cut, feedrate), workpiece material and environmental conditions. Industrial feedback will be used to ensure coating optimization to meet the needs of real users.The broader/commercial impacts of this project will be the potential to significantly improve the performance of micro tools. An important area of this industry is currently limited by poor micro end mill performance. Improved tooling performance will not only reduce the capital machine cost in this field, but also help realize the miniaturization of existing cutting-edge technology limited by current manufacturing capabilities. The most promising societal benefits of NCD tool coating will be realized in healthcare industry as diamond coatings are essential for the development of next generation biosensors and biomedical devices. This will significantly improve the quality and substantially reduce costs associated with biological sample testing, reducing the financial burden of healthcare expenses on individuals and the country.