Due to the special lattice structure of natural diamond, its structure has strong binding force and directionality, so that diamond has extremely high mechanical properties. As a superhard tool material, diamond has been used in machining for hundreds of years. In the 1950s, synthetic diamond was synthesized in Sweden and the United States, and cutting tools have since entered a period represented by superhard materials.
In the 1970s, polycrystalline diamond (PCD) was synthesized by high-pressure synthesis technology, which solved the problem of scarcity and high price of natural diamond. Although polycrystalline diamond (PCD) has a binder, its hardness and wear resistance are still lower than that of single crystal diamond. However, because the PCD sintered body is isotropic and has no weak bond layer, it is not easy to crack along a single cleavage plane. Therefore, PCD inserts do not need to correct their feed direction for optimal cutting results.
Compared with general cemented carbide, PCD exhibits excellent mechanical properties;
PCD has a strong affinity with iron-based metals, and as a tool, its carbon element is easily diffused during the cutting process, resulting in severe wear. However, when processing other materials such as non-ferrous metals, the affinity is very low, the cutting process is not easy to stick to the knife, and the cutting edge is very sharp, so it can obtain extremely high dimensional accuracy and excellent surface quality.
Diamond or PCD will be carbonized and fail when the temperature in the air exceeds 600 ℃, so it is not suitable for cutting that may generate high temperature.
With the continuous development of cutting tool technology, the processing range has expanded from traditional non-ferrous metal processing to stone processing, wood processing, metal matrix composite materials, glass, engineering ceramics and other materials. The scope of application extends to aviation, aerospace, automobile, and electronics.
|
Processed material |
Processing
methods |
Cutting speed
V(m/min) |
Depth of cut
AP(mm) |
Feed
(mm/r) |
PCD Grades |
|||
|
|
|
|
|
|
DGF16-N |
DGM13-N |
DGR15-N |
|
|
Aluminum alloy: aluminum, cast aluminum，Formed cast aluminum
|
Rough turn |
1000-3000 |
0.1-3.0 |
0.1-0.4 |
☆ |
☆ |
☆ |
|
|
|
Fine turning |
1000-3000 |
0.05-0.8 |
0.03-0.2 |
☆ |
☆ |
☆ |
|
|
|
Milling |
1500-3500 |
0.1-2.5 |
0.05-0.3 |
☆ |
☆ |
☆ |
|
|
High silicon cast aluminum |
Rough turn |
200-700 |
0.1-2.5 |
0.1-0.4 |
|
|
☆ |
|
|
|
Fine turning |
200-700 |
0.05-0.8 |
0.03-0.2 |
|
|
☆ |
|
|
|
Milling |
400-900 |
0.1-2.0 |
0.05-0.3 |
|
|
☆ |
|
|
Copper alloy: Brass, bronze, copper-zinc alloy, magnesium alloy
|
Rough turn |
600-1000 |
0.5-2.0 |
0.1-0.4 |
☆ |
☆ |
|
|
|
|
Fine turning |
700-1200 |
0.05-0.5 |
0.05-0.4 |
☆ |
☆ |
|
|
|
|
Milling |
700-1200 |
0.1-2.5 |
0.1-0.3 |
☆ |
☆ |
|
|
|
Hard Metal Co<15%
|
Rough turn |
20-25 |
0.1-0.5 |
0.1-0.3 |
|
□ |
□ |
|
|
|
Fine turning |
20-30 |
0.05-0.2 |
0.05-0.2 |
|
□ |
□ |
|
|
Hard rubber: Glass, ceramics, graphite, various plastics,
PVC, PA, PE, fiber reinforced plastics (GFK) |
Rough turn |
80-1000 |
1.0-2.0 |
0.1-0.4 |
□ |
☆ |
☆ |
|
|
|
Fine turning |
80-1500 |
0.1-2.0 |
0.05-0.3 |
□ |
☆ |
☆ |
|
|
|
Milling |
200-1000 |
0.1-2.0 |
0.1-0.3 |
□ |
☆ |
☆ |
|
|
Composite Wood Products |
Sawing |
2000-5000 |
|
0.05-1.0 |
☆ |
☆ |
|
|
|
|
Milling |
2000-5000 |
|
0.05-1.0 |
☆ |
☆ |
|
|
Note: 1. ☆Especially suitable □Conditional suitable 2. Feed unit during milling = mm/tooth
