Currently, many people in the mechanical industry use diamond (PCD) cutting tools, but some of the usage areas are not sufficiently understood. They often cannot determine exactly where PCD cutting tools are used in which industries or fields. Below, we will explain the characteristics of PCD cutting tools and their application ranges.
Diamond PCD cutting tools are mainly used for precision machining of difficult-to-process materials such as colored metals and their alloys, unsintered hard alloys, graphite, ceramics, fiberglass, silicon carbide, hard plastics, rubber, various fibers and particle-reinforced composite materials, as well as high hardness and wear-resistant wood.
They have the characteristics of long service life, high production efficiency, high machining surface smoothness, high machining accuracy, etc. Compared with hard alloys and natural diamond cutting tools, PCD cutting tools have higher processing efficiency and lower cost, and are widely used in industries such as automobiles, diesel engines, motorcycles, aerospace, electronics, precision machinery, etc.
1. High-speed cutting of light metals and non-metallic materials:
When cutting aluminum alloy materials with PCD cutting tools, very high speeds can be achieved. When processing colored metals with PCD cutting tools, due to the high hardness of diamonds, the surface has small affinity with metals, and the tool is generally polished into a mirrored surface, it is not easy to produce burrs, and the dimensional stability and surface quality are very good. The tool life can reach several thousand to tens of thousands of pieces, especially suitable for mass production of automobile and motorcycle parts and high-speed large cutting of aircraft parts.
2. Precision and ultra-precision high-speed cutting:
Due to the high bond strength of diamond, mirror processing of non-ferrous metals can be achieved for micro-cutting, which can be used for precision and ultra-precision as well as optical component processing.
On ultra-precision lathes, single crystal diamond cutting tools can be used to achieve spherical mirror processing. The machine tool adopts ultra-precision gas static main spindle and rotary worktable, with radial circular runout error ≤0.3um, and the workpiece uses a high-precision pneumatic chuck, which can achieve fast and high-precision positioning. When machining aluminum parts, the surface roughness can reach Ra≤0.025um.
3. Used for processing new ceramic materials and difficult-to-process materials:
Especially when processing hard-to-machine colored metals and non-metallic materials with high hardness and wear resistance, such as high silicon aluminum alloys, reinforced fiber plastics, heat-resistant alloys, etc., PCD cutting tools have obvious advantages.
In summary, PCD cutting tools have high hardness and long tool life. They are suitable for mass production and special requirements, such as precision cutting of high hardness materials. Now, many tool manufacturers have introduced super hard tools, which generally provide the tool's usage environment and applicable cutting parameters. When using super hard tools, one should not only study the usage parameters provided by the manufacturer but also fully consider actual cutting conditions.
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