As the machining industry continues to evolve, there's a growing demand for cutting tools that not only perform better but also align with sustainable development. Green and environmentally friendly practices are now at the forefront of tool innovation. This shift is driven by both technological advancements and a stronger emphasis on reducing environmental impact.
One of the key goals in modern tool design is to extend the service life of cutting tools while minimizing contamination during the cutting process. Dry cutting is increasingly preferred, as it reduces the need for cutting fluids. When these fluids are still necessary, they should contain only rust inhibitors without any organic compounds, significantly lowering recycling costs and environmental burden.
The diversity of cutting tools and their operational characteristics influence the choice of coatings. Unlike turning or drilling tools, milling cutters must withstand intermittent impacts. Early coating technologies focused primarily on wear resistance, aiming to increase hardness. Coatings like titanium nitride were popular for this reason, but they often had high friction coefficients, leading to excessive heat generation during use.
To prevent overheating that could cause tool deformation and affect machining accuracy, cutting fluids have traditionally been used. However, experts like Luo Baihui, a specialist in gold die-cutting tools, argue that the next step is to develop coatings that not only enhance tool longevity but also provide self-lubrication properties. This would help reduce or eliminate the need for cutting fluids altogether.
Diamond-like carbon (DLC) coatings have shown promise in certain applications, offering excellent mechanical performance. However, research has revealed several limitations. DLC coatings tend to have high internal stress, poor thermal stability, and can react with ferrous metals, causing structural changes from SP3 to SP2. These issues restrict their use mainly to non-ferrous materials, limiting broader application in metal machining.
Recent advancements, however, have led to new types of DLC coatings with an SP2 structure. These coatings achieve hardness levels of 20–40 GPa, exhibit low friction coefficients, and show good moisture resistance. They can be used with cutting coolants and even support dry cutting. Their service life is nearly double that of uncoated tools, and they work effectively on steel materials. This breakthrough has sparked significant interest among coating manufacturers and tool producers.
As research progresses, this new generation of diamond-like coatings is expected to become a game-changer in the cutting industry. With improved performance and sustainability, they represent a major leap forward in tool technology and environmental responsibility.
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