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）切削材料的功能概况，采用不同的烧结工艺生产。对这些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，亚微米颗粒）进行了比较。此外，在各种材料的加工中使用了NbC硬质金属的细微差别，并与wc - 6co刀具的磨损行为进行了比较。结果表明，与WC-6Co相比，这种新型切削材料在干式车削淬硬钢42CrMo4 + QT和相同工艺参数下车削碳钢C45E的刀具寿命更长。研究发现，在vc = 150 m/min的高切削速度下加工C45E时，由于NbC在铁等固体金属中的溶解度较低，产生的弹坑磨损明显减少。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刀具在室温（RT）下的硬度较低，但在加工淬火钢时获得了较长的切削时间，这是由于NbC与WC-6Co相比具有更高的热硬度。在铣削AlSi9Cu4Mg铝合金的过程中，可以实现与WC-6Co相似的刀具寿命，尽管到目前为止NbC的细微差别仍然具有较低的韧性。到目前为止，NbC细微差别已经在实验室规模上生产，并且大部分是通过烧结方法火花等离子烧结（SPS）生产的，这在工业上并不常用。因此，在继续的应用中，工业相关的NbC切削材料的生产方法越来越集中在硬度、强度和韧性值的进一步提高以及防止晶粒生长上。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的细微差别被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式对刀具寿命的影响。使用不同的分析方法来确定磨损的原因。最后，考虑到不同的生产方法和粘结剂材料的细微差别，建立了描述NbC应用和磨损性能的分析模型。

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.