Diamond Tools

Diamond Tools-About Diamond Tools:

Diamond tools and wear-resistant materials in non-ferrous metal processing applications, has excellent adaptability. In the tool material, diamond is the hardest. In a suitable processing conditions, the diamond than high-speed steel, carbide, ceramics and polycrystalline cubic boron nitride are life long. It also has shortcomings, is generally not apply to the processing of ferrous metal materials. But in high-speed mass production, processing, and other materials such as aluminum and graphite, diamond is often the most effective tool.

In the use of diamond tools, users have two options: one is polycrystalline diamond PCD, the other is relatively new chemical vapor deposition CVD diamond.

Diamond Tools-PCD diamond;

Polycrystalline diamond has a natural diamond hardness, strength and abrasion resistance, but did not damage the sensitivity of natural diamond. It is at a high temperature, high pressure, by the polymerization of synthetic diamond particles. In the process, the formation of polycrystalline particles simultaneously bonded to a cemented carbide whole body to improve mechanical strength and impact resistance.
In accordance with GE's super abrasive to the Ministry of, PCD is very suitable for high speed cutting of aluminum, in particular, is required to achieve a good rough surface for the main occasions, it is in the processing of high wear resistance materials, also showed excellent performance. Typically, PCD recommended for cutting high silicon aluminum alloy, but also for brass, copper, bronze and carbon processing. The procedures include the use of cars, boring, profiling, grooving, milling and hole processing.

As the chemical reaction between the diamond and iron, in general PCD does not apply to processing ferrous metal materials. But it can deal with double the processing of metal materials, including aluminum and cast iron combination included. For example: a car parts supplier in the processing of aluminum and cast iron dual metal cylinder, use the knife clamp 305mm diameter face milling cutter, the tip arc 2.36mm, with repair knife, cutting speed 304.8m/min, feed 0.10 mm / tooth, depth of cut 5mm, processing up to 5000 cylinder body, the blade need only be shifted again.

GE's manager of planning applications that the application of PCD, by mass production industry, mainly in the automotive industry increasing aluminum processing speed boost. At the same time, automobile manufacturers to reduce weight and reduce costs, is on the use of metal matrix composites evaluated, and such materials should be used to process PCD. He said: "These materials can not be used carbide cutting tools."

Polycrystalline product manager, said, despite the achievements of the development of PCD gives a very deep impression, but the Ministry of GE Super abrasives are still continuing to work in order to further improve its abrasion resistance.

PCD tools and productivity applications, have many benefits for the process. Although diamond is the hardest materials available, and its material properties and toughness of other issues still need further study. PCD to improve the toughness of a factor, plus cobalt to enter the random alignment between the diamond grains. In addition, the diamond abrasive carbide substrate layer can also play a role in mechanical support, thereby increasing the impact resistance, and tools to facilitate the manufacture of brazing.

Another benefit of PCD is that the various grades of existing series have been used to meet the needs of any non-ferrous metal processing. In general, fine particles of diamond for low wear resistance of materials to be machined surface roughness is very high and the occasion; diamond particles in general as the general machining grades; coarse diamond for roughing the special anti-wear materials, but the surface roughness of less demanding place.
Diamond Tools-CVD diamond:
Chemical vapor deposition CVD diamond, is a high wear resistance of pure diamond material, non-adhesive. Diamond deposition is divided into two forms: one is the thick-film diamond deposition as a whole, separate sheets, then cut to desired size; the other is the thin-film diamond deposition in the carbide blade or rotary cutter on.


So far, CVD diamond is the most promising applications processed graphite. However, Norton Diamond Film Company was being sold for various uses CVD diamond for processing non-ferrous metals, plastics and composite materials. Norton's manager that the application of technology, CVD diamond is suitable for almost all non-ferrous metals. In the intermittent cutting high silicon aluminum alloy and pre-sintered carbide, brass, copper and carbon fiber materials, processing, good results are achieved. Norton has also believe: CVD diamond in the processing of a wide range of aluminum and other materials, including 6061, when, and PCD can be matched.Norton's application technology manager also believes that, CVD diamond and PCD compared to the major advantage of cutting edge quality. Although CVD is also polycrystalline, but it does not contain cobalt binder, is a pure diamond, so the cutting edge is continuous. This would use a higher cutting speed and get a better surface roughness, because the tool is not easy to get hot. He also firmly believes that BUE is not a problem of CVD diamond.

By Norton Company information, CVD diamond's thermal conductivity 50% higher than the PCD. The reason is that CVD diamond blade as a whole, the heat can be immediately derived. The PCD inserts to heat conduction through the Co - diamond complex, the thermal conductivity of the fan.
CVD diamond also has a low coefficient of friction. Carbide and PCD are bonded workpiece material, CVD diamond is non-stick. At the same time, low coefficient of friction also make the CVD diamond cutting tools can withstand a greater load, so that the cutting faster and more efficiently.
Presented in the use of CVD diamond thermal stability and chemical stability. The PCD and carbide in this respect by the impact of binder with metal components. Into hydrochloric acid in the CVD diamond, nothing will happen. However, if the PCD diamond into them, acid will eat the cobalt binder. This means that CVD diamond can withstand some of the materials generated in the processing of acid attack, such as phenolic resins, rubber, urine, abdominal, lower carbonate and so on.
Although all forms of diamond, including PCD at high temperature to be super alloys and ferrous metals or elements in some of the chemical reaction, but we all know, for most materials, the diamond is still chemically inert. PCD and carbide with cobalt binder because the cutting temperature will occur when high chemical stability reduce the phenomenon. CVD diamond without bond, to avoid this phenomenon. In addition, CVD diamond as well as good lubricity and thermal conductivity, it has a high-speed and dry cutting using the key advantage.