PCD (Polycrystalline Diamond) extrusion tools are renowned for their cost-effectiveness and high efficiency in surface mirror processing. These tools are designed to achieve high-precision, finely polished surfaces through cold extrusion processing. The surface undergoes plastic deformation by applying pressure that exceeds the material's yield point, resulting in a superior finish.
Applications in Precision Parts Processing
PCD extrusion tools are particularly effective for mirror polishing precision parts, such as optical molds made from mold steel with hardnesses ranging from HRC45 to HRC65. The PCD ball head extruder ensures stable processing outcomes, a superior surface finish, and significantly enhanced processing efficiency.
Key Features of PCD Extrusion Tools
1. Versatility: Capable of rolling processing for various tapers, arcs, and outer circles.
2. Surface Roughness: Achieves a surface roughness of less than Ra0.08 post-extrusion.
3. Durability: Long service life with multiple usable points on the rotating spherical surface.
4. Material Compatibility: Can extrude materials with hardness up to HRC60.
5. Enhanced Wear Resistance: Increases workpiece wear resistance by 15%.
6. Improved Fit Tightness: Enhances the tightness of parts fit.
7. Material Suitability: It is suitable for processing mold steel, graphite, glass, ceramics, carbon fiber, sapphire, and more.
8. Customization: Supports non-standard customization to meet specific requirements.
Case Study
Material: Die Steel
- Hardness: HRC52
- Workpiece Diameter: 20mm
- Workpiece Depth: 3mm
- Ball R Angle: 0.75
- Surface Roughness (Ra): ≤30nm
- Rotational Speed (n): 40,000 rpm
- Feed Rate (Vf): 400 mm/min
- Depth of Cut (Ap): 0.005 mm
- Width of Cut (Ae): 0.005 mm
- Work Time: 8.5 hours
- Cooling Method: Wet cooling
Conclusion
PCD extrusion tools offer a robust solution for achieving high-quality surface finishes in various materials. Their versatility, durability, and ability to enhance wear resistance and fit tightness make them indispensable in precision parts processing. They deliver consistent and reliable results for standard or custom applications.
