Enhancement of process reliability in micro machining by application of geometrically defined cutting edges made of new cutting materials for micro processing

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Micro milling tools made of cemented carbide have shown dramatically tool wear during machining of non-ferrous-metals as well as steel for molding tools. In addition cemented carbide tools achieve limited machining quality and tool life. The aim of this research project is the improvement in performance of milling tools for micro machining through the application of geometrically defined cutting edges made of PCD, PcBN and CVD-thick-film-diamond. Subgoal of the project is the development of a reliable and cutting material independent tool geometry. Furthermore the tool diameter is d < 1 mm with maximum aspect ratio. In this regard the wear resistance as well as the economic efficiency will be improved. Based on the knowledge of achievable cutting edge radii and the machining behavior, micro milling tools with cutting edges made of solid PCD, CVD-thick-film-diamonds and PcBN are designed reliably. Beyond that a basic analysis of the processing behavior of micro milling tools with cutting edges made of solid PCD, CVD-thick-film-diamonds and PcBN with geometrically defined cutting edges is intended. Moreover an investigation of the cutting edges made of PCD and CVD-thick-film-diamonds manufactured by grinding and polishing, laser, wire-EDM and focused ion beam is proposed.