PCD tools have the characteristics of high hardness, high compressive strength, good thermal conductivity and wear resistance, and can achieve high machining accuracy and machining efficiency by high-speed cutting. It has a wide range of applications, extending to aviation, aerospace, automotive, electronics, stone and other fields.
1. Cutting speed
PCD tools can be cut at extremely high spindle speeds, but the impact of cutting speed changes on machining quality cannot be ignored. Although high-speed cutting can improve machining efficiency, under high-speed cutting conditions, the increase in cutting temperature and cutting force can cause damage to the tool tip and cause vibration of the machine tool.
When machining different workpiece materials, the reasonable cutting speed of PCD tools is also different. For example, the reasonable cutting speed of milling Al2O3 laminate floor is 110~120m/min; the reasonable cutting speed of turning SiC particle reinforced aluminum matrix composite materials and silicon oxide based engineering ceramics is 30~40m/min.
2. Feed
If the PCD tool feed is too large, the residual geometric area on the workpiece will increase, resulting in an increase in surface roughness; if the feed is too small, the cutting temperature will rise and the cutting life will decrease.
3. Cutting depth
Increasing the cutting depth of the PCD tool will increase the cutting force and the cutting heat, thereby increasing the tool wear and affecting the tool life. In addition, increasing the depth of cut is prone to cause chipping of PCD tools.
The cutting performance of PCD tools with different particle size grades is different when processing different workpiece materials under different processing conditions. Therefore, the actual cutting parameters of PCD tools should be determined according to the specific processing conditions.
The main forms of tool wear are abrasive wear, adhesive wear (cold welding wear), diffusion wear, oxidation wear, thermoelectric wear, etc. The failure mode of PCD tool is different from that of traditional tool MyCIMT, which is mainly manifested as polycrystalline layer damage, adhesive wear and diffusion wear.
The research shows that when PCD tools are used to process metal matrix composites, the main failure mode is bond wear caused by microscopic intergranular cracks caused by diamond grain defects. When machining high hardness and high brittleness materials, the bonding wear of PCD tools is not obvious; on the contrary, when machining low brittle materials (such as carbon fiber reinforced materials), the tool wear increases, and the bonding wear plays a leading role at this time.
Due to its good processing quality and economical processing, PCD tools show advantages that are incomparable with other tools in the field of cutting processing such as non-metallic materials, non-ferrous metals and their alloy materials, and metal matrix composite materials. With the deepening of the theoretical research of PCD cutting tools and the further promotion of application technology, the status of PCD cutting tools in the field of superhard cutting tools will become increasingly important, and its application scope will be further expanded.
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