PCD Cutters to Replace Diamond Cutters

Currently, monocrystalline diamond, PCD, and CVD diamond have become the materials for cutters production. Choice of diamond materials should be based on the prpperty of processed materials and the demand for processing. Besides the technological demand, economic demand and environmental protection demand should be taken into consideration.

PCD Materials

PCD is the most commonly used diamond materials in production. it is not only suitable for machining, but also applied widely in auto, motor cycles, rapid trains, oil, chemical engineering, construction, wood processing and aerospace fields. In the fields of automobiles and motor cycles, PCD is used in pin holes, cylinder blocks, gearboxes, carburetor, and other wear resistant parts. While most of these aluminum matrix composites are high in silicon (more than 20%), the hard particles, such as Sic, are distributed in aluminum alloy substrate, just like the abrasive grains in the grinding wheels. The hard particles will exert an grinding force on the cutters and make cutting edge wear. The higher the hardness of the hard particles, the larger the sizes, the more the quantities, the faster the cutting edge become wear. Therefore, it is difficult to use traditional cutters to hard alloy cutters due to the short working life.

Diamond is the hardest material known in the world. It has been proved to be the best material for aluminum matrix composite cutters. The cutting speed of aluminum matrix composites processed by PCD diamond can reach as high as 8001000m per minute. The working life of the cutters is several times or dozens of times higher than hard alloy. The processed surface roughness can reach Ra0.0250.012μm. When processing carbon fiber of fiberglass reinforced plastics with PCD cutters, the cuttings are powdery, and the grinding temperature is low. The cutting length is ten times of the hard alloy cutters, while the abrasion is less than one0third of the hard alloy cutters.

PCD cutters are also suitable for processed hard alloy cutters and wear resistant non-metallic materials, such as ceramics, rubber, graphene, glass, and all kinds of durable wood. The property of PCD cutters mainly depends on their application and processing procedures. Different kinds of PCD cutters vary in cutting performance due to different constituents. Usually PCD cutters are applicable to rough finish and production that requires high fracture toughness. CVD thick film and monocrystalline cutters are mostly used in high-speed fine machining and semifinishing.

Author: Liwei Chu 
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