PCD is a synthetic polycrystalline diamond.
It is made of natural or synthetic diamond powder and binder (including cobalt, nickel, and other metals) in a certain proportion, sintered at high temperature (1000-2000 ℃) and high pressure (5-100,000 atmospheres). Generally, it will be sintered into a PCD composite sheet with a fixed diameter and thickness, and then through cutting, welding, sharpening, and other processes to make a PCD tool.
Usually, the layer thickness of the PCD composite sheet is about 0.3-1.0mm, which can be made into a PCD milling cutter, PCD inserts, PCD turning tool, PCD reamer, PCD drill, and various non-standard custom tools, etc.
Since the diamond powder will be carbonized when the PCD temperature is above 800 degrees Celsius, it cannot process iron-containing materials.
PCD tool processing material:
1. Non-ferrous metals and their alloys - such as aluminum, copper, gold, silver and their alloys, die-casting aluminum, red copper, cemented carbide, etc. For die-casting aluminum parts, CDW085 and CDW002 are commonly used, with better processing finish and brightness.
2. Composite materials - such as graphite, carbon fiber composite materials, glass fiber composite materials, aluminum-based silicon carbide, glass fiber reinforced plastic, metal-based composite materials, etc. For composite materials, CDW302 and CDW010 materials are commonly used, with good durability and long life.
3. Other non-metal difficult-to-process materials - such as ceramics, engineering plastics, hard rubber products, semiconductor materials, etc.
CBN (Cubic Boron Nitride) is a material second only to diamond in hardness. It is formed by adding soft hexagonal boron nitride (white graphite) to the catalyst under ultra-high temperature and high-pressure conditions. It is a new type of inorganic superhard material, which has been widely used in the processing fields of different industries.
1. High hardness cast iron - such as high chromium cast iron, alloy cast iron, nickel hard cast iron, and white cast iron are all high hardness cast iron, and typical parts are rollers, industrial pumps, etc. For high hardness cast iron, the commonly used BN-K1 material has significant advantages.
2. High hardness steel parts - such as high manganese steel, high-speed steel, hardened steel, etc. Typical parts include rolling mortar wall, high-speed steel roll, hardened gear/gear shaft, bearing, ball screw, mold, etc. The commonly used CBN materials for high hardness steel parts are BN-S20, BN-S200, BN-H10, BN-H21, etc.
3. Gray cast iron (HT150/200/250/300, etc.) - such as engine block/cylinder head, brake disc, brake drum, pulley, clutch pressure plate, etc. are all gray cast iron castings. Commonly used CBN materials are BN-S300 and BNK30.
4. Other difficult-to-process materials - such as powder metallurgy, superalloy materials, nickel-based, iron-based, cobalt-based, and other high-hardness surfacing/spray welding/laser cladding / thermal spray material workpieces. Common CBN materials are BN-K50, BN-H20, BN-K10, etc.
PCD tools have similarities with CBN tools, and both can be used for high-speed cutting. The automotive field is the best application field for PCBN tools and PCD tools. Quenched gears, bearings, automotive wheel bearing units, cylinder liners, ball cage universal joints, various shaft parts, synchronizer gear hubs, aluminum alloy engine cylinder blocks, cylinder liners, pistons, hubs, gearboxes, and other parts.
With the use of high-speed CNC machine tools, the processing time can be greatly shortened and the processing efficiency can be improved.
---POST: Cynthia Lee
