Analysis of the influence quantities on the adhesion of CVD diamond layers on carbide tools

在该项目的第一个资助期间，开发了钴和镍结合的新型碳化铌 (NbC) 切削材料的功能特性，该材料采用不同的烧结工艺生产。对这些 NbC 细微差别的材料特性进行了测试，并与市售碳化钨钴（WC-6Co，亚微米颗粒）进行了比较。此外，NbC硬质合金的细微差别被用于各种材料的加工，并将磨损行为与WC-6Co刀具进行了比较。结果表明，与WC-6Co相比，新型切削材料在淬硬钢42CrMo4 QT的干车削以及使用相同工艺参数的碳钢C45E车削中实现了更长的刀具寿命。研究发现，在以vc = 150 m/min的高切削速度加工C45E时，发生月牙洼磨损的情况明显减少，这是由于NbC在铁等固体金属中的溶解度较低。 NbC 材质的刀具寿命优势随着切削速度的增加而增加。尽管 NbC 切削刀具在室温 (RT) 下的硬度较低，但在加工淬硬钢时实现了更长的切削时间，这归因于 NbC 与 WC-6Co 相比具有更高的热硬度。在铣削铝合金 AlSi9Cu4Mg 时，可以实现与 WC-6Co 类似的刀具寿命，尽管 NbC 细微差别迄今为止仍具有较低的韧性。到目前为止，NbC 细微差别已在实验室规模中生产，并且大部分通过火花等离子烧结 (SPS) 的烧结方法生产，这在行业中并不常见。因此，在后续应用中，NbC切削材料的工业相关生产方法越来越关注于进一步提高硬度、强度和韧性值以及防止晶粒长大。通过调整刀具的微观和宏观几何形状以适应每种工件材料的磨损行为，NbC 的细微差别可用于各种材料的车削和铣削加工，分析切削过程中的行为。对每种材料进行了参数研究，并研究了不同冷却方法对刀具寿命的影响。使用不同的分析方法确定磨损原因。最后，考虑到 NbC 的不同生产方法和粘合剂材料的细微差别，准备了一个用于描述应用和磨损行为的分析模型。

During the first funding period of this project, the functional profile of cobalt- and nickel-bonded, novel niobium carbide (NbC) cutting materials was developed, which were produced using different sintering processes. The material properties of these NbC nuances were tested and compared with a commercially available tungsten carbide cobalt (WC-6Co, submicron grain). Furthermore, the NbC hard metal nuances were used in the machining of various materials and the wear behavior was compared with the WC-6Co-tools.It could be shown that the new cutting material achieves longer tool life compared to WC-6Co in dry turning of hardened steel 42CrMo4 + QT and also in turning of carbon steel C45E using the same process parameters. It was found that during the machining of C45E with a high cutting speed of vc = 150 m/min, significantly less crater wear occurs, which is due to the lower solubility of NbC in solid metals such as iron. The tool life advantages of the NbC grades increase with increasing cutting speed. Despite the lower hardness of the NbC cutting tool at room temperature (RT), higher cutting time was achieved during the machining of hardened steel, which is attributable to a higher hot hardness of the NbC compared to WC-6Co. During the milling of the aluminum alloy AlSi9Cu4Mg, similar tool lifetime as with WC-6Co could be achieved, although the NbC nuances so far still have a lower toughness.Up to now, the NbC nuances have been produced in the laboratory scale as well as for the most part by means of the sintering method Spark Plasma Sintering (SPS), which is not customary in the industry. In the application for continuation, therefore, the industrially relevant production methods of the NbC cutting materials are increasingly focussed with a further increase in hardness, strength and toughness values as well as prevention of grain growth. By adapting the micro- and macro-geometry of the tools to the wear behavior per workpiece material, the NbC nuances are used in the turning and milling processing of a wide range of materials analyzing the behavior in cutting process. A parameter study is carried out for each material and the influence of different cooling methods on the tool life is investigated. The causes of wear are determined using different analytical methods. Finally, an analytical model for the description of the application and wear behavior is prepared, taking into account different production methods and binder materials of the NbC nuances.