From Micro to Nanometric Grain Size CVD Diamond Tools

Abstract

ABSTRACTCVD diamond coated tools are developed for applications as different as turning of cemented carbides and bone drilling. The diamond films are deposited by Hot Filament Chemical Vapor Deposition (HFCVD), with grain sizes varying from conventional micrometric (12 μm) to nanometric (< 100 nm) and film thickness up to 50 μm. Silicon nitride (Si3N4) ceramics are chosen for the base material in order to guarantee maximal adhesion. Both the micrometric and nanometric CVD diamond grades endure the cemented carbide turning showing slight cratering, having flank wear as the main wear mode. However, nanocrystalline diamond present the best behavior regarding cutting forces (<150 N) and tool wear (KM=30 μm, KT=2 μm and VB=110 μm) and workpiece surface finishing (Ra=0.2 μm). In the case of the dental drilling experiments, a polymeric laminated test block is used to simulate the human mandible and maxilla. The temperature rise during drilling is monitored to prevent overheating above 42–47 °C that is known to cause tissue death and implant failure. It is possible to drill with a CVD diamond Si3N4 coated tool with significantly lower forces (fourfold smaller), lower rise in temperature (4°C less), lower spindle speeds (100 rpm) and higher infeed rates (30 mm/min), when compared to the commercial steel (AISI 420) drill bits.