Mechanical Machining

In mechanical machining, the quality of the tools directly determines the machining effect. And with the continuous development of science and technology, the quality and performance of materials are gradually improving, making its processing difficulties continue to increase. In this situation, more stringent requirements are put forward for the performance and quality of the tools. Tools made of superhard materials represented by synthetic diamond and cubic boron nitride have great advantages in mechanical machining due to their excellent hardness and toughness. The applications of superhard material tools can not only improve the efficiency of machining, but also provide guarantee for products quality and reduce the cost of processing and manufacturing. At present, the application of superhard material cutters in machining has become more and more extensive.

Types of Superhard Materials Used in Mechanical Machining

At present, the superhard materials used to manufacture tools in the field of machining are mostly CVD diamond, polycrystalline diamond (PCD) and polycrystalline cubic boron nitride (PCBN). The cutting tool made of CVD diamond has good thermal conductivity and low friction coefficient, which can be used in the machining of ceramics, aluminum, non-ferrous metals and other materials. However, this kind of tool has the disadvantages of relatively poor toughness and thermal stability, and thus it is easy to carbonize in the process of use. This makes the CVD cutting tool unsuitable for the processing of pure steel materials. PCD is prepared from diamond, but compared with diamond, it has a higher polymerization degree, making it less susceptible to serious damage in the cutting process. In addition, PCD has a higher wear resistance, a broader source and a lower cost. Therefore, the tool made of PCD is widely used in the field of machining. Although the wear resistance of PCBN is not high, PCBN has more prominent stability and thermal conductivity, relatively low the friction coefficient and good corrosion resistance, which makes the PCBN tool often used in the extraction processing process.

Applications

Superhard material tools are widely used in mechanical machining, mainly including the following aspects:

• Turning and milling: Turning process is to use a tool to process materials with high hardness such as hardened steel. PCBN tools are commonly used to process hardened steels whose strengths exceeding 45HRC, which not only improve the grinding effect of steel parts, appropriately expand the depth of cutting, but also greatly promote the processing efficiency and reduce the manufacturing cost. In milling process, tools made of PCD material are often used, which can be used for aluminum alloy and glass milling. The maximum machining speed of PCD tools can reach 4000 m/min, which greatly saves the processing time.

• Boring: Boring process is mostly used in the processing of automotive engines, in which the PCBN tool is mainly used. The tool has a long history of use, consistent size and can precisely control the precision of processing. In addition, CVD tools can also be used in this process. For example, CVD tools can be used for tungsten carbide cylinder boring processing with max cutting speed of 0.5 m/s and can process multiple parts at the same time.
• Reaming and drilling: Reaming is mostly used for the processing of small holes in hard castings, or the processing of hardened steel. Due to the high hardness of the type of material and the high requirement of workpiece accuracy, PCBN electroplating reamer is usually required. The object of drilling processing is mainly non-metallic materials such as pottery and glass. PCD tools are frequently used in this process. One of the advantages of processing glass or porcelain with PCD tools is that special holes or conical holes can be machined according to customer requirements.

Meet Alfa Chemistry

At Alfa Chemistry, we are committed to providing the highest quality superhard materials and services to meet the needs of the mechanical machining. We have successfully developed various CVD diamonds, polycrystalline diamonds and polycrystalline cubic boron nitrides, which provide the best performance for turning, milling, boring, reaming and drilling process. With our advanced products and unparalleled expertise, we are confident that we can provide superior superhard material tool solutions for the mechanical machining and help our customers gain a competitive advantage in the market with higher product performance and lower production costs to achieve their goals.