Cutting tools need to reduce cutting pollution and reduce costs

With the rapid advancement of science and technology, the demand for improved material surface properties has significantly increased. Over the past few decades, the emergence of various vapor deposition techniques has driven remarkable progress in surface engineering. These technologies not only meet mechanical performance requirements like wear resistance, friction reduction, and corrosion protection, but also play a vital role in functional materials related to electromagnetics, optics, optoelectronics, thermal management, superconductivity, and biotechnology. Surface engineering enables cost-effective metal materials to perform more efficiently, making it a key approach in developing new coatings and thin films with broad application potential. As machining technology continues to evolve, cutting tools face increasingly stringent demands. In addition to longer service life, there is a growing need to minimize cutting pollution and prioritize dry cutting methods. When cutting fluids are unavoidable, they should ideally contain only rust inhibitors without organic compounds, which can significantly lower recycling costs and reduce environmental impact. The variety of cutting tools and their operational characteristics during use influence the selection of tool coatings. Unlike turning or drilling, milling cutters must account for intermittent impacts. Early coating development focused mainly on wear resistance, aiming to increase hardness. Coatings such as titanium nitride, while effective, have a high friction coefficient (0.4–0.6), leading to significant heat generation during operation. To prevent tool deformation and maintain machining accuracy, cutting fluids are often used. To address the challenge of reducing or eliminating cutting fluids, modern tool coatings must not only extend tool life but also provide self-lubrication. Diamond-like carbon (DLC) coatings have shown promise in machining certain materials like aluminum, titanium, and their composites. However, traditional DLCs suffer from high internal stress and poor thermal stability. They also exhibit catalytic effects when interacting with ferrous metals, limiting their use to non-ferrous materials. This restriction has hindered broader application in metal machining. Recent research has introduced a new type of DLC based on an SP2 structure, offering hardness between 20–40 GPa. These coatings do not react with ferrous metals, have a low friction coefficient, and show excellent moisture resistance. They can be used with coolant for dry cutting, significantly extending tool life—more than double that of uncoated tools. Their compatibility with steel makes them highly appealing to coating companies and tool manufacturers. As this technology matures, it is expected to become widely adopted in cutting applications in the near future.

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