Diamond tool non-ferrous metal wear-resistant material processing application, has excellent adaptability. Tool material, diamond is the hardest. Under suitable processing conditions, diamond has a longer service life than high speed steel, cemented carbide, ceramics and polycrystalline cubic boron nitride. It also has shortcomings and generally does not apply to the processing of ferrous materials. But high-speed mass production, processing materials such as aluminum graphite, diamond is often the most effective tool.
When using diamond tools, users have two choices: one polycrystalline diamond (PCD) and another newer chemical vapor deposition (CVD) diamond.
The use of performance has long been proven. Polycrystalline diamond has natural diamond hardness, strength and wear resistance, but no natural diamond damage sensitivity. It is made of synthetic diamond particles under high temperature and high pressure. During the process, polycrystalline particles are formed and bonded to a solid carbide substrate to improve mechanical strength and impact resistance.
According to GE's Super Abrasives Division, PCD is ideal for high-speed aluminum cutting. It is suitable for high-surface roughening applications. It also exhibits excellent performance when processing high-abrasion materials. Typically, PCD is recommended for cutting high-silicon aluminum alloys, as well as for brass, copper, bronze, and carbide processing. The use process includes car, boring, profiling, grooving, and milling.
Due to the chemical interaction between diamond and iron, PCD is generally not suitable for processing ferrous materials. But it can deal with the processing of bimetallic materials, including aluminum and cast iron combinations. For example, when an auto parts supplier processes aluminum-aluminum-iron bimetallic cylinder blocks, a 305 mm diameter face-to-face face milling cutter is used, with a tool edge arc of 2.36 mm, with a light-cutting knife, a cutting speed of 304.8 m/min, and a feed of 0.10 mm/tooth. The cutting depth is 5mm. After processing 5000 cylinders, the blade needs to be indexed once.
GE's application planning manager believes that PCD applications are driven by the mass production industry, and the major automotive industries are increasingly driving aluminum processing speeds. At the same time, automakers are evaluating metal matrix composites to reduce weight and reduce costs, and such materials are processed using PCD. He said: "This type of material cannot be machined with carbide tools."
The production manager of polycrystalline products said that although the development achievements of PCD have been very impressive, GE Super Abrasives continues to work to further improve its anti-wear properties.
The application efficiency of PCD tools has brought many benefits to the process. Although the diamond's existing materials are the hardest, the problem of material properties and toughness still needs further study. A factor that improves PCD toughness, adding cobalt to the random unaligned diamond grains. In addition, the cemented carbide substrate can also mechanically support the diamond abrasive layer, thereby increasing the impact resistance and tooling for easy brazing.
Another advantage of PCD is that it can meet the needs of any non-ferrous metal processing. In general, fine-grained diamond is used in applications where the wear resistance of the material to be processed is low and the surface roughness is very high; granular diamond is generally used as a general grade for machining; coarse-grained diamond is used for roughing of extraordinary wear-resistant materials, but the surface is rough. The requirements are not high.
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