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

在加工有色金属和模具用钢的过程中，硬质合金制造的微细铣刀出现了严重的刀具磨损。此外，硬质合金刀具的加工质量和刀具寿命有限。本研究项目的目的是通过应用由PCD、PcBN和CVD-厚膜金刚石制成的几何定义的刀具来改善用于微加工的刀具的性能。该项目的子目标是开发一种可靠的、与切割材料无关的刀具几何形状。此外，刀具直径为d&lt；1 mm，具有最大纵横比。在这方面，将提高耐磨性和经济效益。基于可实现的刀具刃口半径和加工行为的知识，可靠地设计了由固体PCD、CVD厚膜金刚石和PcBN制成的刀具。在此基础上，对由实心PCD、CVD厚膜金刚石和PcBN组成的刀具的加工行为进行了基本分析。此外，还对PCD和CVD厚膜金刚石的磨削抛光、激光、电火花线切割和聚焦离子束等加工方法的刀具刃口进行了研究。

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.