Due to the high hardness and brittleness of precision ceramic materials, the technical requirements for hole processing are relatively strict. It is required that the material has no obvious cracks after drilling;
High requirements for the smoothness of the hole wall: the hole wall is smooth and free of burrs and cracks;
High dimensional accuracy requirements: the minimum aperture is only 0.1mm, and there are high requirements for aperture consistency and hole roundness, and the accuracy error is generally required to be controlled within 20μm.
This poses a greater challenge to tools for microhole machining. Take the micro-hole machining of zirconia ceramics as an example to see the excellent performance of MORE SUPERHARD PCD micro-drills.
Processing material: zirconia ceramics
Material hardness: about 9 on the Mohs scale
Difficulties in processing:
▶The hole is easy to chip and crack
▶Low machining accuracy and poor hole wall finish
▶Low processing efficiency and low tool life
Processing parameters:
Speed S: 20000r/min
Feeding speed F: 5mm/min
Each processing depth Q: 0.05mm
Effective processing depth Z: 5.0mm
Processing effect:
The drilling time for a single hole is 189S, the drilling life is about 200+ holes, and the hole accuracy error is controlled within 20um.
Starting hole: Φ0.452mm
End hole: Φ0.449mm
Surface chipping: <0.01mm
Processing material: 99 alumina ceramics (Rockwell hardness HRA: above 86)
Difficulties in processing:
▶the material has no obvious cracks after drilling (ceramic materials have high hardness and brittleness);
▶the hole wall has high requirements for smoothness, and the hole wall is smooth and free of burrs and cracks;
▶High dimensional accuracy is required, and the minimum aperture is only 0.1mm.
▶At the same time, there are high requirements for aperture consistency and hole roundness, and the accuracy error is generally required to be ≤30μm.
Processing parameters:
Speed S: 20000r/min
Feeding speed F: 10mm/min
Each processing depth Q: 0.15mm
Effective processing depth Z: 12.5mm
Processing effect: 158S for single-hole drilling, and the drilling life is about 600 holes
Starting hole: Φ0.802mm
End hole: Φ0.793mm
Surface chipping: <0.01mm
