Cutting tool for new material processing

In order to meet the challenges of environmental protection in today's world, the trend of automobile manufacturing production focuses on reducing fuel consumption and reducing vehicle weight. These requirements are achieved by the development of new materials with higher mechanical properties. When the development of these materials achieves the desired goals, the downside is that these new materials are always stiffer and more resistant to processing. With the wide application of new materials in various industrial parts, tool materials have also been rapidly developed accordingly. Let us focus on new tools that save time and improve economy. In the polycrystalline diamond (PCD) tool series, progress is getting faster and faster. The first synthesis was in the 1950s, and PCD is now used worldwide and is seen as a powerful cost-saving tooling solution. It is an unparalleled tool material for a range of non-ferrous workpiece materials such as aluminum alloys, plastics, reinforced plastics, ceramics, graphite and a wide range of other workpiece materials.

PCD tool characteristics
Diamond
Diamond is essentially a pure carbon. There are two known forms of carbon: graphite and diamond. In the graphite form, the carbon atoms are arranged in a hexagonal shape with a large atomic spacing in one plane, which makes the material very soft. However, in the case of diamond, carbon atoms are arranged in an equiaxed or cubic crystal structure. It is this unique arrangement of closely connected carbon atoms that makes diamond the hardest known material for humans.

Preparation Process
PCD is obtained by artificial synthesis of a large number of randomly oriented diamond particles under extremely difficult conditions. It is prepared by sintering selected diamond particles at high pressures and temperatures. The sintering process is strictly controlled within the diamond stabilization zone, thus producing an extremely hard and wear resistant structure.

characteristic
Diamond in a polycrystalline form provides a powerful cutting tool that provides excellent hardness and resulting wear resistance combined with the excellent toughness of the polycrystalline structure. In addition, diamond has the highest thermal conductivity of all tool materials, allowing heat to be quickly transferred from the cutting edge.

In addition to the high affinity of PCD and iron, PCD does not bond to the workpiece material, and under the correct cutting parameters, the built-up edge is minimized. All Secomax PCD tools feature a mirror-finished rake face that provides the lowest coefficient of friction and a smooth cutting edge.

Workpiece material
Aluminum alloy
Aluminum alloys have become an ideal material for the transportation industry to reduce weight. Although aluminum alloy production has greater initial demand for energy consumption, it has proven to be more beneficial in long-term operation, and these alloys will outperform other competing materials. Pure aluminum has low hardness and corrosion resistance. For example, the addition of alloying elements such as copper or magnesium will give the material a higher strength. There are many kinds of aluminum alloys on the market, the most famous ones are the 2000 and 6000 series used in the automotive and aerospace industries. There is a clear dividing line between forged and cast aluminum alloys, each with several different grades and a wide range of hardening properties.

For silicon alloys with low to medium silicon (Si) content, PCD offers the best wear resistance for milling applications and roughing. The most common problem encountered should be built-up edge. This happens even with very high cutting speeds when machining low silicon aluminum alloys. The geometry and quality of the cutting edge must be carefully applied.

With such parameters, the longer the contact time with the workpiece, the higher the heat generated, the direct effect of which is the shortening of the tool life.

For processing high silicon aluminum alloys, the wear resistance of PCD is fully utilized. Some studies on these materials have highlighted the relationship between tool wear and silicon particle size, and the larger the silicon particles, the higher the wear resistance of the workpiece. The quality of the tool will play an important role in the success of aluminum alloy processing applications: low runout will prevent inconsistent load on the cutting edge.

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