Correct use of polycrystalline diamond tools in cutting

When cutting aluminum alloy materials, the wear life of cemented carbide tools is only about 5% of PCD tools, and the roughing cutting speed of cemented carbide tools is about 120m/min, while PCD tools are even roughing high-silicon aluminum alloys. The cutting speed can also reach about 360m/min. Tool manufacturers recommend using fine-grained (or medium-grained) PCD grades to process silicon-free and low-silicon aluminum alloy materials, and coarse-grained PCD grades to process high-silicon aluminum alloy materials. If the surface finish of the milled workpiece fails to meet the requirements, a wiper blade with a smaller grain size can be used to trim the surface of the workpiece to obtain a satisfactory surface finish.

The correct application of PCD tools is the prerequisite for obtaining satisfactory processing results. Although the specific reasons for tool failure vary, it is usually caused by incorrect use of objects or methods. When ordering PCD tools, users should correctly grasp the scope of application of the tools. For example, when using PCD tools to process ferrous metal workpieces (such as stainless steel), because diamond is very easy to chemically react with the carbon elements in the steel, it will cause the PCD tools to wear quickly, so the correct choice for processing hardened steel should be PCBN tools.

But generally speaking, in order to reduce the cutting force and prevent the buildup of built-up edge, PCD tools should use a positive cutting angle. When processing high-silicon aluminum alloys (especially when PCD tools are used instead of cemented carbide tools for processing), the clearance angle of PCD tools should preferably be slightly smaller than the relief angle used by the original cemented carbide tools (such as 25°). Improve the cutting performance of PCD tool cutting edge on high silicon aluminum alloy. The positive rake angle of the PCD tool should not be too large, because the larger the rake angle of the tool, the lower the strength of the cutting edge. In other words, the smaller the relief angle of the PCD tool, the higher the strength of the cutting edge. (Guide: Analysis of the performance and use of six commonly used measuring tools and cutting tool steels)

In order to increase the cutting edge strength as much as possible on the premise of ensuring that the tool has a positive cutting angle, Mastertech Diamond Products of the United States welded the CNMX blade with a negative rake angle to the PCD tool tip and formed a positive cutting angle. In this way, the negative blade The rake angle not only provides high cutting edge strength, but also does not affect the normal cutting of the tool. When preparing the cutting edge of a PCD tool, there is no need to do too much processing on the diamond tip. For PCD milling cutters, the cutting edge can be slightly sharpened. In addition, a certain axial inclination of the cutting edge can also help improve the PCD tool. Cutting performance.

The successful application of PCD inserts does not only depend on the reasonable selection of tool geometric parameters and cutting parameters (such as the commonly used feed rate range of PCD turning tools from 0.13mm/r (fine turning) to 0.38mm/r (rough turning)) , Sometimes it is necessary for the tool supplier to provide solutions to the problems encountered in the use of the tool. For example, a large-scale automobile parts processing workshop uses PCD blades provided by Ju0026M Diamond Tools for milling grooves. Originally, each PCD diamond blade can process 1,500 parts. However, the chips generated by the machining will damage the surface of the part. For this reason, Ju0026M proposed a solution of machining a radial chip breaker on the top of the diamond blade by using the EDM (electric discharge machining) process, and specially customized 50 blades, which effectively solved the problem. This question. Now the number of parts processed by each PCD blade has been increased from 1500 to 4300.

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