Currently, single crystal diamond, PCD (or PCD/CC), and CVD diamond have been successfully used as materials for cutting parts such as turning tool, boring tool, drill bit, reamer, milling cutter, shaping tool and cutting tool.
The varieties of diamond materials must be selected according to the nature of the materials and the requirements of the processing. In addition to meeting the technical requirements, they should also meet the requirements of economic and environmental performance.
PCD and PCD/CC materials
PCD and PCD/CC are common diamond materials in production. It is not only applicable to the general mechanical processing field, but also widely used in automobile, motorcycle, high-speed train, petroleum, chemical, construction, timber processing and aerospace industries. In the field of automobile and motorcycle, PCD and PCD/CC are applicable to the aluminum alloy piston’s skirt, pin hole, cylinder body, transmission, carburetor and other wear-resistant parts. Most of these components are aluminum matrix composites with high silicon content (Si>12%). Its interior has hard particles of high hardness (such as SiC with a hardness of up to 3000 — 3500HV) distributed in the aluminum alloy matrix, which will scratch and impact the cutting edge of the cutter just like the abrasive particles in the grinding wheel, and make the cutting edge wear quickly. The higher the hardness of hard particles, the larger the size of particles, and the more particles, the faster the tool wear. As a result, it is difficult to process with conventional carbide tools, and the tool life is very low or impossible to use at all. Diamond is known as the harder material in the world.
The machining speed of aluminum matrix composites with PCD diamond is up to 800 ~1000m/min, the tool life is several times or even dozens times higher than that of hard alloy, and the roughness value of the machined surface is up to Ra0.025~0.012μm.
When CFRP and fibreglass reinforced plastics (FRP) are processed with PCD (or PCD/CC) cutters, the chip is powdery, the cutting temperature is low, and the cutting length is 10 times that of the k-type carbide cutters, while the wear is less than 1/3 of the carbide cutters.
PCD (or PCD/CC) cutting tools are also suitable for processing pre-burned hard alloy and wear-resistant non-metallic materials such as ceramics, rubber, graphite, glass and various kinds of wear-resistant wood.
The performance of PCD tools depends on their application and the processing process involved, but the selection of appropriate brand and particle size also has an impact. Different kinds of PCD blades have great difference in cutting performance due to their different components.