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Figure 234 shows examples of the different morphologies observed on using a scanning electron microscope CVD diamond tools are excellent for machining highly abrasive nonferrous alloys such as Al Si, and at the time were inexpensive compared to PCDS [39] The CVD diamond combines the advantages of both single-crystal diamonds and PCDs which are stated as follows: (i) binder-free diamond coating with a higher hardness, wear resistance, thermal resistance than PCDs, (ii) highly dense polycrystalline pure diamond coating without the inherent shortcoming of a single-crystal cleavage Also, the lower fracture toughness of the CVD diamond than of PCDs is somewhat offset by the fact that its higher thermal conductivity and improved thermal stability allow CVD diamond tools to run at faster speeds without generating harmful levels of heat CVD diamonds find applications in making inserts, drills, reamers, end mill and routers and offer an advantage over PCDs such as multiple edges per insert and pressed-in chip breakers for machining gummy materials such as aluminium 6061 In Figure 235, a diamond coated insert is compared with a PCD insert, and in Figure 236, a diamond coated tool edge is compared with an SCD tool [41]



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Fig. 12-9. N-P junction ( rst joined).

10 m

Fig 234: Morphologies of films grown in a hot filament CVD reactor: (a) triangular {111} morphology, (b) {110}

Fig. 12-10.

morphology, (c) {100} morphology and (d) cauliflower morphology [39]

(b) (a) Fig 235: (a) A diamond coated carbide insert with a tool holder and (b) a polycrystalline diamond tipped insert in the tool holder [41]

N-P junction (depletion region).

(a) rake angle [41]





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an illusion, since it is just the lack of electrons. The barrier electrons also repulse those in the semiconductor lattice in the p-type side, which is why the holes ow toward the barrier. Eventually, though, the forces all balance out. The barrier of locked electrons is the depletion zone. The free electrons have been depleted, and the holes have been taken away ( lled) so they can be considered to be depleted too. While the two halves of the depletion zone may have electrical charge, it is not a movable charge. Everything is stuck in place, so the depletion zone is an insulator.

247 Design of Diamond Tools [42, 43]

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To design a diamond tool correctly, it is important to have knowledge of the damage patterns first Three patterns usually occur: normal wear, fracture and cleavage damage For preventing cleavage and reducing the normal wear, the diamond should be oriented before grinding To avoid a fracture, the cutting edge and tool nose should be strengthened [42, 43] Design principles The diamond tool should be of a high quality and have a long tool life It is also necessary that a suitable raw diamond of a high utilization ratio, and is easy to grind, is chosen Design sequence The design sequence is as follows: 1 Determine the geometric parameters of the tool 2 Orient the diamond crystal, and draw the orientation figure 3 Determine the grinding sequence and the grinding direction of every operation (technological regulation) 4 Stipulate the requirement for the raw diamond, the cutting edge and the roughness of the tool faces 5 Obtain the working drawing

The next step in creating a diode is to attach two wires to it, one on each side. When you apply a voltage across the diode in the forward direction, the current ows. Why Figure 12-11 shows the forward bias circuit. The battery, or other power source, is pushing electrons into the N side of the diode. As external electrons are pushed into the N side the pressure builds up until it begins to overcome the repulsion of the depletion zone. This shrinks the depletion zone and electrons are free to move again. The electrons continue to move across the barrier. They can kick electrons out of their holes and out the other side of the diode. This gives us current through the diode. The pressure needed to shrink the depeletion zone takes away some of the pressure from the circuit. This is the voltage drop across the diode.

Example: Design of the Diamond Precision Turning Tool To design a diamond precision turning tool to be used on an automatic lathe to obtain a roughness Rz = 014 m, on a brass work piece The design sequence is as follows:

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