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The correct use of PCD cutters
- May 07, 2018 -

When aluminum alloy materials are machined, the wear life of the carbide tool is only about 5% of the PCD tool, and the cutting speed of the hard alloy tool is about 120m/min, while the cutting speed of the PCD tool can reach about 360m/min even in the rough machining of high silicon aluminum alloy. The tool manufacturer recommends the use of fine particle (or medium particle) PCD brand to process silicon and low silicon aluminum alloy materials, and use coarse particle PCD brand to process high silicon aluminum alloy material. If the surface finish of the milling machine can not meet the requirement, the light trimming blade with smaller grain size can be used to repair the workpiece surface so as to obtain a satisfactory surface finish.

The correct application of PCD cutter is the premise of satisfying machining effect. Although the specific reasons for tool failure vary, they are usually caused by incorrect use of objects or methods. When ordering PCD tools, users should correctly grasp the applicable scope of cutters. For example, when processing black metal workpiece (such as stainless steel) with a PCD tool, the chemical reaction between the diamond and the carbon element in the steel will lead to the rapid wear of the PCD tool. Therefore, the correct choice of the hardened steel should be the PCBN tool.

But generally speaking, in order to reduce the cutting force and prevent the formation of built-up edge, PCD cutting tools should adopt tangent chipping. In the process of processing high silicon aluminum alloy (especially when using PCD tool instead of hard alloy tool), the rear angle of PCD tool is better than that of the original cemented carbide tool (such as 25 degrees), to improve the cutting performance of the high silicon aluminum alloy with the cutting edge of the PCD tool.  The front angle of the PCD tool should not be too large, as the larger the front angle of the tool, the lower the strength of the cutting edge. In other words, the smaller the rear angle of the PCD tool, the higher the strength of the cutting edge. In order to improve the cutting edge as much as possible on the premise of cutting the cutting tool to the tangent angle, American MastertechDiamondProducts company welded the CNMX blade with the negative front angle to the tip of the PCD tool and formed the tangent angle, so that the negative front angle of the blade not only provides higher cutting edge strength, but also does not affect the normal cutting tool. Cutting. When the cutting edge of the PCD tool is prepared, it is not necessary to do a lot of process treatment on the tip of the diamond tool. For the PCD milling cutter, the cutting edge can be slightly sharpened. In addition, a certain axial inclination of the cutting edge can also help to improve the cutting performance of the PCD tool.

The successful application of the PCD blade not only depends on the rational selection of the geometric parameters and cutting parameters of the tool (for example, the feed rate range of the PCD tool is 0.13mm/r (fine car) to 0.38mm/r (Rough car)), and sometimes it also needs the tool supplier to provide a solution to the problems encountered in the tool use. For example, a large automobile parts processing workshop uses the PCD blade provided by J&M diamond tool company to process the milling slot, and each piece of PCD diamond blade can process 1500 parts, but the chip produced by the machining will damage the surface of the parts. Therefore, J&M company proposes to use EDM (discharge machining) technology to process the diamond blade at the top of the tool. The solution of the radial chip breaker is specially customized for 50 blades, thus effectively solving this problem. Now the number of parts processed by each PCD blade has increased from 1500 to 4300 pieces.


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