Hey there! As a supplier of DLC Coated End Mills, I've seen firsthand how crucial it is to understand the impact of DLC (Diamond-Like Carbon) coating on cutting forces when dealing with hard-to-machine materials. In this blog, I'm gonna break down what this impact means for your machining operations.
First off, let's talk about what hard-to-machine materials are. These are materials like titanium alloys, nickel-based superalloys, and hardened steels. They're tough nuts to crack because they have high strength, low thermal conductivity, and can be chemically reactive. When you try to cut these materials, you face a bunch of challenges, and one of the big ones is dealing with high cutting forces.
Cutting forces are basically the forces exerted on the cutting tool during the machining process. High cutting forces can lead to a whole host of problems. They can cause excessive tool wear, which means you'll have to replace your tools more often. This not only adds to your costs but also leads to downtime as you change out the worn - out tools. High forces can also result in poor surface finish on the workpiece, which is a no - no if you're aiming for high - quality parts. And in some cases, it can even cause the workpiece to deform, ruining the part altogether.
So, where does DLC coating come in? Well, DLC coating is a super thin, hard, and smooth coating that can be applied to cutting tools. It has some pretty amazing properties that can really change the game when it comes to cutting hard - to - machine materials.
One of the main ways DLC coating affects cutting forces is by reducing friction. Friction is a major contributor to high cutting forces. When the cutting tool rubs against the hard - to - machine material, there's a lot of resistance, and this resistance shows up as high cutting forces. The smooth surface of the DLC coating acts like a lubricant. It allows the tool to glide more easily through the material, reducing the frictional forces. As a result, the overall cutting forces are lower.
Another benefit of the DLC coating is its high hardness. Hard - to - machine materials are, well, hard. A regular uncoated tool might start to wear down quickly when trying to cut through them, and as the tool wears, the cutting forces increase. But the DLC coating is extremely hard, so it can withstand the abrasion from the hard material for a longer time. This means that the tool maintains its sharpness for a longer period, and a sharp tool requires less force to cut through the material compared to a dull one.
Let's take a look at some real - world examples. Say you're using a 1 Flutes Aluminum Processing End Mill on a titanium alloy. Without the DLC coating, the cutting forces can be so high that the end mill might wear out after just a few passes. But when you apply the DLC coating, you'll notice that the cutting forces are significantly reduced. The tool can make more passes before it starts to show signs of wear, and the surface finish of the titanium part is much better.
Similarly, for a 2 Flutes DLC Milling Drills used on a nickel - based superalloy, the DLC coating can have a huge impact. The reduced cutting forces mean that the drill can penetrate the material more easily. You won't have to apply as much pressure, and there's less risk of the drill breaking or getting stuck in the material.
In addition to reducing cutting forces, the DLC coating also has an impact on the heat generated during the machining process. High cutting forces often lead to more heat generation, which can further damage the tool and the workpiece. Since the DLC coating reduces cutting forces, it also reduces the amount of heat produced. This is great because it helps to preserve the integrity of the tool and the workpiece.
But it's not all sunshine and rainbows. There are a few things to keep in mind when using DLC - coated tools. For example, the coating thickness needs to be just right. If it's too thick, it might start to peel off during the machining process, which can actually increase the cutting forces. And the application process of the DLC coating is also crucial. A poorly applied coating won't provide the same benefits as a well - applied one.
Now, if you're in the business of machining hard - to - machine materials, you're probably thinking about how you can get your hands on these amazing DLC - coated tools. Well, that's where I come in. As a supplier of DLC Coated End Mills, I can offer you high - quality tools that are designed to reduce cutting forces and improve your machining operations. Whether you need 1 Flutes Aluminum Processing End Mill or 2 Flutes DLC Milling Drills, I've got you covered.
By using our DLC - coated tools, you can expect longer tool life, better surface finish on your workpieces, and reduced costs in the long run. If you're interested in learning more about our products or want to discuss your specific machining needs, don't hesitate to reach out. I'm here to help you make the most of your machining operations and take your productivity to the next level.
In conclusion, the DLC coating has a significant impact on cutting forces in hard - to - machine materials. It reduces friction, maintains tool sharpness, and helps to control heat generation, all of which lead to lower cutting forces and better machining results. So, if you're tired of dealing with high cutting forces and their associated problems, it's time to give DLC - coated tools a try.
References
- Klocke, F., & Eisenblätter, G. (1997). Machining of difficult - to - machine materials. Annals of the CIRP, 46(2), 531 - 556.
- Erdemir, A. (2001). Tribology of diamond and diamond - like carbon films. Wear, 250(1 - 12), 410 - 425.
- Schipper, D. J., & de Groot, M. J. (2006). Friction and wear of diamond - like carbon coatings. Tribology International, 39(12), 1619 - 1628.
