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<p>This study aims to enhance the service life of cutting tools and improve machining quality for mica glass-ceramic workpieces through the application of three diamond coating variants: microcrystalline (MCD), micro-nano composite (MNCD), and nanocrystalline (NCD) on cemented carbide tools. Although diamond coatings are widely recognized for their superior hardness and wear resistance, their performance in glass-ceramic machining under variable cutting conditions remains insufficiently investigated. To address this knowledge gap, we systematically examine the influences of coating microstructure and cutting parameters (spindle speed, feed rate, cutting depth, and width) on workpiece surface roughness, cutting vibration, and tool wear resistance using an orthogonal experimental design. Key findings reveal that diamond-coated tools demonstrate substantially better performance than uncoated counterparts. Specifically, NCD coatings achieve the minimal surface roughness (Ra = 0.95&#xa0;µm, representing a 45% reduction compared to uncoated tools), while MCD coatings exhibit the longest tool life (30% longer than NCD variants). Optimal vibration suppression occurs at 3000&#xa0;rpm spindle speed combined with 300&#xa0;mm/min feed rate, resulting in 22-40% lower vibration amplitudes than those observed under higher parameter combinations. The wear resistance hierarchy follows MCD &gt; MNCD &gt; NCD, which correlates with MCD’s enhanced interfacial adhesion and columnar grain morphology. These results establish quantitative guidelines for selecting diamond coatings and cutting parameters to advance precision machining of glass-ceramics in aerospace and biomedical industries. </p>

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Diamond Coating Tool for Glass-Ceramic Machining: An Experimental Investigation of Coating Types and Cutting Conditions

  • 期刊论文

  • 发表日期：

    2025年5月1日

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  • Tongxiang Zheng,
  • Lixiu Zhang,
  • Zhengwei Fu,
  • Yuhou Wu,
  • He Lu,
  • Xu Bai

摘要

This study aims to enhance the service life of cutting tools and improve machining quality for mica glass-ceramic workpieces through the application of three diamond coating variants: microcrystalline (MCD), micro-nano composite (MNCD), and nanocrystalline (NCD) on cemented carbide tools. Although diamond coatings are widely recognized for their superior hardness and wear resistance, their performance in glass-ceramic machining under variable cutting conditions remains insufficiently investigated. To address this knowledge gap, we systematically examine the influences of coating microstructure and cutting parameters (spindle speed, feed rate, cutting depth, and width) on workpiece surface roughness, cutting vibration, and tool wear resistance using an orthogonal experimental design. Key findings reveal that diamond-coated tools demonstrate substantially better performance than uncoated counterparts. Specifically, NCD coatings achieve the minimal surface roughness (Ra = 0.95 µm, representing a 45% reduction compared to uncoated tools), while MCD coatings exhibit the longest tool life (30% longer than NCD variants). Optimal vibration suppression occurs at 3000 rpm spindle speed combined with 300 mm/min feed rate, resulting in 22-40% lower vibration amplitudes than those observed under higher parameter combinations. The wear resistance hierarchy follows MCD > MNCD > NCD, which correlates with MCD’s enhanced interfacial adhesion and columnar grain morphology. These results establish quantitative guidelines for selecting diamond coatings and cutting parameters to advance precision machining of glass-ceramics in aerospace and biomedical industries.