The objective of the proposed project is to achieve a decisive improvement in the efficiency, flexibility, environmental compatibility and quality of machining operations on lightweight aluminium alloy components through the use of CVD diamond coated cutting tools. The investigations are focused on aluminium alloys representative for the product spectra of the involved end users and for a growing number of industrial applications in many fields, especially the transport industry. CVD diamond coating technology provides a low priced opportunity for transferring the excellent machining properties of diamond (long tool lives combined with high removal rates, low wearinduced part size errors and low adhesion) already familiar from the use of polycrystalline diamond (PD) to complex geometry tools as they are frequently used for the mass production of lightweight components. PD is not feasible for use in such applications, or can be used only at extremely high cost. CVD diamond coatings could fill this gap for special tools as well as profile tools and can also massively improve the performance of standard tools for the machining of aluminium alloys. Additionally the properties of a diamond surface offer the opportunity to reduce or avoid the use of coolants and thereby improve the environmental compatibility of the machining process. The still insufficiently resolved coating substrate adhesion problems of CVD diamond films are the reason, why application of diamond films is still limited to machining of primarily abrasive materials (FRC, graphite, MMC etc.). These problems have to be solved in order to withstand the combined highly abrasive and adhesive wear attack occurring during machining of the considered aluminium casting and extrusion alloys, especially sub eutectic ones. In order to solve these problems, the project adopts a systematic approach aimed at developing guidelines for design, construction and application of CVD diamond coated tools suited for the machining of these alloys. The entire machining system , i.e. the substrate, its geometry, the surface treatment, the coating properties and the process parameters are taken into account to achieve an optimum match between them. Coating, tool and process technology will be developed and optimised, together with tool reconditioning methods for milling, turning, drilling and threading operations. The project activities consequently involve tool manufacturers, coalers and end users. Introduction of the developed processes in the participating companies will be supported by a preparation of a manual and by training in a seminar. Apart from utilisation of the results in the manufacturing operations of the participating end users, progressive commercial exploitation and marketing may come about via the participation of the tool manufacturers and the coaler.
Funding SchemeCRS - Cooperative research contracts
5916 PS Venlo
5928 PX Venlo
5854 ZH Bergen