CVD diamond sheet ( thick film, > 250 mu m) tools have been available
for several years. However, commercially useful thin-film (<50 mu m th
ick) diamond-coated carbide tools have been introduced only recently,
indicating that long-standing technical problems related to diamond-ca
rbide adhesion have been largely resolved. Improved coating adhesion l
eads to more reliable and predictable performance in the cutting envir
onment. Surface characteristics of the coating on the tool rake surfac
e affects chip formation and on flank surfaces, the workpiece surface
roughness. Diamond-coated tools can meet or exceed the tool life provi
ded by conventional polycrystalline diamond tools in some applications
, but typically fall short in matching workpiece finishes. Nevertheles
s, diamond-coated tools are starting to play an important role in mach
ining non-ferrous and non-metallic materials.