Micro milling performance assessment of diamond-like carbon coatings on a micro-end mill

Abstract

In micro milling, unpredictable tool life and premature tool failures are the major constraints for its industrial applications, and prolongation of the tool life so as to enhance the tooling performance presents great challenges. Appropriate coating techniques potentially offer a feasible and promising solution. In this study, diamond-like carbon films are deposited on a Ø500 µm diameter tungsten carbide (WC) micro-end mill by the plasma-enhanced chemical vapour deposition process. Coating characterisation has been undertaken and the diamond-like carbon coatings are found in good coverage on the tool except for a slight delaminating on the edge corners. Besides, the surface of the amorphous coatings is much smoother than that of WC. In addition, comprehensive cutting performance of the diamond-like carbon coated tool in dry slot milling of Al 6061-T6 has been compared with those of uncoated tools in both dry and wet conditions. It is observed that the use of diamond-like carbon coatings can reduce the cutting forces, lessen the tool wear, improves the surface roughness and minimise the micro-burr formation as compared to the corresponding performance of an uncoated tool in dry cutting. However, the performance improvement is still unreachable to those resulting from the cutting fluid influence.