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Fig 230: Crystal orientation of a single-crystal diamond tool and typical geometry [37]
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carbon (caused by the heat generated during cutting) Excessive heat will burn or crack a diamond tool The best protection against heat is an abundant supply of cutting fluid with no interruptions However, certain applications may be conducted successfully without the use of any cutting fluid In order to minimize tool fracture, a single-crystal diamond must be resharpened as soon as it becomes dull [2] Edge Technologies Inc has developed an atom-by-atom chemical machining processes that can produce cutting edges on single-crystal Fig 231: Various types of diamond cutting tools [25] diamond (SCD) cutting tools that appear smooth up to a magnification of 10,000x Moreover, it allows the edge of the diamond tool to be formed along the diamond s strong crystallographic planes, so that the cutting edge is the strongest possible ETI s tools are made from Sumitomo Electric s (Chicago) synthetic single-crystal diamonds that are known as Sumicrystal UP These are synthesized under a pressure of 50,000 atm and a temperature of over 1,300 C in Sumitomo s ultra-highpressure apparatus Sumicrystals are very clean, synthetic single-crystal diamonds, giving excellent fracture strength and hardness characteristics and are thus suitable for ultra-precision cutting
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246 Diamond Coated Tools
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Diamond coatings make use of a substrate only as a support The two substrates in use are carbides and silicon nitride ceramics In the case of carbides, the mismatch with diamond coatings on account
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of thermal conductivity is more than offset by the price of the substrate and the ability to have chip geometry moulded onto it For SiN substrates, the cost of the substrate is prohibitive, and the ability to have chip breaker moulds makes them unattractive Unlike PCDs, coated diamonds are thin and conform to the chip geometry on the carbide substrate, which is a major advantage [38] By using chemical vapour deposition (CVD) techniques, diamond can be deposited over large areas The earliest method of producing diamonds at a reasonable deposition rate was developed in the Soviet Union Figure 232 shows the schematic diagram of the experimental apparatus The method is based on the transport of carbon from a graphite secretor to the substrate by means of a hydrogen catalyst The graphite was heated Fig 232: A schematic diagram for diamond deposition [38] by optically to a temperature of about 2,000 C A fraction of the hydrogen gas in contact with the graphite was converted to atomic hydrogen, which etched the graphite, resulting in a number of hydrocarbon gas species such as methane and acetylene The hydrocarbons diffused to the cooler substrate held at about 1,000 C, where it reacted to deposit diamond [39] For a better understanding, three CVD methods for diamond deposition are briefly described Thermal CVD (Hot filament, TF CVD) The hot filament method was the first practical method to produce diamond in a systematic way because it had a greater degree of process control Figure 233 (a) shows a schematic diagram of a hot filament reactor at NIST A hydrogen and methane feed gas mixture is allowed to pass over a hot filament The quality of a diamond produced improves with decreasing methane fractions in the feed gas The plasma is generated by a hot filament (W, Ta, Re) heated to 2,000 C or higher, around which hydrogen is dissociated into highly reactive atomic hydrogen, and hydrocarbon compounds are stripped from a hydrogen-forming radical In the simplest case, that of methane, CH4, a methyl radical, CH3, or probably an HC radical is formed The substrate is at a distance of between 5 and 20 mm from the heated filament, and its temperature is between 700 and 1,000 C The gas consumption is typically H2:CH4 = 99:1 Under these conditions, the growth rate is of the order of 1 m/h Figure 233 (b) illustrates a hot filament CVD reactor In this method, a small amount of the filament evaporation occurs and contaminates the growing diamond film This metallic contamination is not too much of a constraint for coatings used in mechanical applications of such as tools or general wear parts [40] However, it is a nuisance when envisaging electronic applications such as active components as well as optical sensor devices
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