Diamond coated tool and method of manufacturing the diamond coated tool
AssigneeOsg Corporation
InventorHiroyuki Hanyu
Life of this patent
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Abstract
A diamond-coated tool including: (a) a substrate; and (b) a diamond coating disposed on the substrate. The diamond coating is formed of diamond crystals grown on the substrate. Each of the diamond crystals has a diameter not larger than 2 μm as measured on an outer surface of the diamond coating, and/or a length not larger than 2 μm as measured in a direction in which each of the grown diamond crystals has expanded by its growth. The diamond coating preferably consists of a plurality of layers.
Claims16
A diamond-coated tool comprising:
- a substrate;
- and
- a diamond coating disposed on said substrate, said diamond coating including a plurality of layers superposed on each other,
- wherein each of said plurality of layers is formed of grown diamond crystals each of which has a diameter not larger than 2 μm.
A diamond-coated tool comprising:
- a substrate;
- and
- a diamond coating disposed on said substrate, said diamond coating including a plurality of layers superposed on each other,
- wherein each of said plurality of layers is formed of grown diamond crystals each of which has a length not larger than 2 μm as measured in a direction in which said each of said diamond crystals has expanded by growth thereof.
A diamond-coated tool comprising:
- a substrate having a surface roughened to have a predetermined degree of surface roughness;
- and
- a diamond coating consisting of a plurality of layers and disposed on the roughened surface of said substrate, said diamond coating being formed of diamond crystals grown on said substrate, each of said diamond crystals having a diameter not larger than 2 μm as measured on an outer surface of said diamond coating, said diamond coating having a maximum thickness of not larger than 14 μm;
- wherein said roughened surface has a roughness curve whose maximum height Ry is not larger than 1 μm and whose ten-point height of irregularities Rz is 0.2-0.5 μm;
- and
- wherein said substrate has a rake face, a flank face and a cutting edge which is defined by an intersection of said rake face and said flank face, said cutting edge being rounded as a result of roughening of said surface of said substrate such that said cutting edge is displaced in an inward direction of said substrate by a distance not larger than 5 μm.
A method of manufacturing a diamond-coated tool comprising a substrate and a diamond coating disposed on said substrate, said method comprising:
- a nucleus bonding step of bonding nucleuses to said substrate which is disposed in a reactor of a chemical vapor deposition device;
- and
- a crystal growing step of growing diamond crystals in said reactor in accordance with a chemical vapor deposition method, such that said diamond crystals grow from said nucleuses,
- wherein said nucleus bonding step and said crystal growing step are repeatedly implemented for thereby forming, on said substrate, said diamond coating including of a plurality of layers superposed on each other, wherein each of said plurality of layers is formed of grown diamond crystals each of which has a diameter not larger then 2 μm.
A method of manufacturing a diamond-coated tool which includes a substrate having a surface, and a diamond coating disposed on said surface of said substrate, said substrate having a rake face, a flank face and a cutting edge that is defined by the an intersection of said rake face and said flank face, said method comprising;
- a surface roughening step of roughening said surface of said substrate of said tool, such that the roughened surface has a roughness curve whose maximum height Ry is not larger than 1 μm and whose ten-point height of irregularities Rz is 0.2-0.5 μm, and such that said cutting edge is rounded to be displaced in an inward direction of said substrate by a distance not larger than 5 μm;
- and
- a coating forming step of forming said diamond coating on said roughened surface of said substrate, said diamond coating including a plurality of layers by growing diamond crystals in accordance with a chemical vapor deposition method, such that each of said plurality of layers is formed of grown diamond crystals each of which has a diameter not larger than 2 μm as measured on an outer surface of said diamond coating, and such that said diamond coating consists of a plurality of layers and has a maximum thickness not larger than 14 μm.
Dependencies are inferred from the claim text.