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内，开发了钴和镍结合的新型碳化铌（NbC）切削材料的功能轮廓，这些材料使用不同的烧结工艺生产。这些NbC细微差别的材料性能进行了测试，并与市售的碳化钨钴（WC-6Co，亚微米晶粒）。此外，NbC硬质合金细微差别被用于加工各种材料，并与WC-6Co刀具的磨损行为进行了比较，可以表明，新的切削材料实现了更长的刀具寿命相比，WC-6Co在干车削淬火钢42 CrMo 4 + QT，也在车削碳钢C45 E使用相同的工艺参数。发现在以vc = 150 m/min的高切削速度加工C45 E期间，发生显著较少的凹坑磨损，这是由于NbC在诸如铁的固体金属中的较低溶解度。NbC牌号的刀具寿命优势随着切削速度的增加而增加。尽管NbC切削工具在室温（RT）下的硬度较低，但在淬硬钢的加工期间实现了较高的切削时间，这归因于NbC与WC-6Co相比具有较高的热硬度。在铝合金AlSi 9 Cu 4 Mg的铣削过程中，尽管NbC颗粒的韧性仍然较低，但刀具寿命与WC-6Co相似。到目前为止，NbC颗粒已经在实验室规模上生产，而且大部分是通过火花等离子烧结（SPS）的烧结方法生产的，这在行业中并不常见。因此，在继续申请中，NbC切削材料的工业相关生产方法越来越关注硬度、强度和韧性值的进一步增加以及防止晶粒生长。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的原因。最后，分析模型的应用和磨损行为的描述准备，考虑到不同的生产方法和粘结剂材料的NbC的细微差别。

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.