PCD grain size
The choice of PCD grain size is related to the cutting tool processing conditions. PCD with high strength, good toughness, good impact resistance, and fine grain is selected when designing tools for precision machining or ultra-precision machining. Coarse grain PCD cutting tools can be used for general roughing. The grain size of PCD material has a significant impact on the wear and breakage performance of cutting tools.
Research has shown that the larger the PCD grain size, the better the wear resistance of the cutting tool.
Blade thickness
Generally, the layer thickness of PCD composite sheet is about 0.3-1.0mm, and the total thickness after adding the hard alloy layer is about 2-8mm. A thinner PCD layer thickness is beneficial for the electric discharge machining of the blade.
When PCD composite sheets are welded to the tool body material, the thickness of the hard alloy layer should not be too small to avoid delamination caused by stress difference between the two material bonding surfaces.
Structural design
The geometric parameters of PCD cutting tools depend on specific processing conditions such as workpiece conditions, cutting tool materials, and structures. Since PCD cutting tools are commonly used for precision machining of workpieces with small cutting thicknesses (sometimes even equal to the cutting edge radius of the tool), which belong to microcutting, the back angle and the rear face quality have a significant impact on the machining quality. Smaller back angle and higher rear face quality can play an important role in improving the machining quality of PCD cutting tools.
There are various ways to connect PCD composite sheets with tool bars, including mechanical clamping, welding, and interchangeable.
Cutting speed
Polycrystalline diamond cutters can be used for cutting at extremely high spindle speeds, but the impact of changing cutting speeds cannot be ignored. Although high-speed cutting can improve processing efficiency, cutting temperature and cutting force will increase in high-speed cutting state, causing tool tip damage and machine tool vibration.
When processing different workpiece materials, the reasonable cutting speed of PCD cutting tools is also different. The suitable cutting speed for milling Al2O3 reinforced floor is 110-120m/min, and that for turning SiC particle-reinforced aluminum-based composite materials and silica-based engineering ceramics is 30-40m/min.
Feed rate
If the feed rate of PCD cutting tools is too high, the residual geometric area on the workpiece will increase, leading to an increase in surface roughness. If the feed rate is too low, the cutting temperature will increase, and the cutting life will be reduced.
Cutting depth
Increasing the cutting depth of PCD cutting tools will increase the cutting force and cutting heat, thereby aggravating tool wear and affecting tool life. In addition, increasing the cutting depth can easily cause the PCD cutting tool to collapse.
Different grades of PCD cutting tools with different grain sizes have different cutting performance when machining different workpiece materials under different processing conditions. Therefore, the actual cutting parameters of PCD cutting tools should be determined based on specific processing conditions.
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