Because of their high hardness, PCD diamond cutting tools are currently only suited for milling non-ferrous metals, aluminum, copper, composite materials, and graphite products on a year-to-year basis. PCD diamond cutting tools demonstrate exceptional wear resistance in the finishing of some ferrous metals or tiny residual machining, as well as the finishing of non-ferrous metals when the cutting temperature is well controlled.
The advantages of using a PCD cutter to process aluminum workpieces include cutter life, metal removal rate, and other benefits. However, the downside is that the cutter is expensive, resulting in high processing costs. In the machinery manufacturing industry, this point has gained traction. However, the research and application of PCD diamond cutting tools have changed dramatically in recent years.
In terms of performance, today's aluminum materials aren't what they used to be. In order to optimize productivity and processing quality when processing various newly created aluminum alloys, the grade and geometric characteristics of the PCD cutter must be carefully set to suit the individual processing needs.
Another difference in polycrystalline diamond cutters is the lower machining cost, which has been greatly decreased as a result of a combination of competitive market pressures and advancements in cutter manufacturing methods. These trends have resulted in a rise in the use of PCD cutters in the machining of aluminum materials, though the cutter's appropriateness is determined by the materials being machined.
A carbide cutter's roughing speed when cutting aluminium alloys is around 120m/min, while a PCD cutter's roughing speed can be around 360m/min even when roughing high-silicon aluminium alloys. For cutting silicon-free and low-silicon aluminum alloys, the cutter manufacturer suggests fine-grained PCD grades. High-silicon aluminium alloys are machined with coarse-grained PCD grades. If the milled workpiece's surface finish does not match the standards, the workpiece can be trimmed with a smaller grain size trimmer insert to achieve a good surface finish.
To achieve satisfactory machining, the PCD cutter must be used correctly. Although the exact causes of cutter failure vary, they are almost always due to improper item or manner of usage. When purchasing a PCD cutter, the user should be informed of the cutter's range of appropriateness.
In order to limit cutting pressures and avoid the formation of chip pockets, the PCD cutter should be utilized at a positive cutting angle. In order to increase the cutting performance of the PCD cutter cutting edge on high silicon aluminium alloys, the back angle of the PCD cutter should preferably be somewhat lowered compared to that of the original carbide cutter while machining high silicon aluminium alloys. The positive front angle of the PCD cutter should not be too great, too, because the higher the front angle of the cutter, the weaker the cutting edge; conversely, the smaller the PCD cutter's back angle, the weaker the cutting edge. In other words, the stronger the cutting edge is, the smaller the back angle of the PCD cutter.
High pricing were once a key barrier to PCD (polycrystalline diamond) cutters' broad acceptance, but that position has improved dramatically. PCD cutter sales are beginning to drop as manufacturing technology improves. Furthermore, the cost of producing PCD cutters is decreasing, and the cutter manufacturing method is improving. The quality of diamond grinding wheels used for polycrystalline diamond cutters has improved dramatically over the last decade, while the cost has decreased significantly.
The field of polycrystalline diamond cutters is improving with the rapid advancement of technology. Consistent product dimensions are ensured with a long cutter life. As a result, the use of polycrystalline diamond cutters in the field of application will certainly continue to grow.
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