This Small Business Innovation Research (SBIR) Phase I project wil explore high rate/high precision machining of hard nonferrous alloys, composites, and ceramics using cutters made from a new material, tricontinuous diamond-tungsten carbide (WC)-cobalt (Co) (TDWC). Currently, polycrystalline diamond (PCD) is used in machining; however, low impact resistance does not allow machining of parts with interrupted cuts, and PCD's large grain size limits its application in precision machining. TDWC is a continuous composite consisting of intercalated diamond and WC-Co that exhibits granite cutting volumes characteristic of PCDs and will have impact resistance characteristic of WC-Co. Phase I will focus on design and fabrication of TDWC based cutters and will demonstrate their performance for high rate machining of difficult-to-manufacture materials. Phase II will develop TDWC sintering of nanograined materials for high precision tools, scaled for fabrication of conventional-size industrial cutters. TDWC based cutters are expected to revolutionize machining in the nonferrous, composite, and ceramics manufacturing industries, allowing high rate high precision machining of these advanced materials with significant reduction in manufacturing cost and increase in productivity. Commercial sales of TDWC-based inserts are anticipated for Phase III.
