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, and 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 machining applications: low runout will prevent inconsistent load on the cutting edge
For PCD tools, the development of wear increases with the cutting speed until the cutting speed is higher than the turning point that causes the wear to rise rapidly. When the tool life is shortened, the cutting speed should be reduced. Tool life is largely independent of feed. High feed rates typically provide faster metal removal rates without shortening tool life as long as the cutting edge does not collapse. However, it should not exceed half the value of the tool nose radius. For cutting depths, Seco Tools recommends a maximum of 65% of the cutting edge length. The polished surface of the Secomax PCD insert means that coolant is not required. However, coolant can help you when there is built-up edge around the cutting edge or chip buildup.
Metal matrix composite
Metal matrix composites (MMC) are made of aluminum or titanium aluminum as the matrix, which is by far the most common matrix material. Addition to the matrix material is a ceramic reinforcing agent, most commonly in the form of granules, but occasionally more fibrous forms are more difficult to process. A range of ceramic materials are used for MMC, but the most common one is Si. According to the required wear resistance of the material, the added content is 15% to 40%.
In the following parts, these materials are gradually replacing heavy materials like cast iron: brake discs, engine blocks, pistons, cylinder liners.
When processing MMC, the cutting speed should be compatible with the ceramic content of the material. The higher the content of the ceramic reinforcing agent, the more wear resistant the workpiece is, so the cutting speed should be lower in order to protect the cutting edge. Positive angle cutting edges are generally accepted during aluminum alloy processing, but negative angle inserts provide a reinforced cutting edge for heavily reinforced materials.
Bimetal material
Processing two different materials that appear on one part is often a big challenge. One of the most common applications is face milling of silicon-aluminum materials with grey cast iron cylinder block engine blocks. Machining these bimetallic parts poses a challenge to the tool supplier, and the tool material that is handy when machining one of the metals is usually not very effective for the other metal. For face-to-face milling of silicon-aluminum engine blocks, the solution is to use a PCD.
When using PCD, you must consider the following conditions: PCD is the perfect cutting tool for machining aluminum alloys. It can be processed at very high cutting speeds while maintaining excellent tool life. Processing iron-based metal gray cast iron with PCD will result in rapid chemical wear. Chemical wear requires heat to develop it, so in order to minimize chemical wear on the PCD tool, the cutting speed should be reduced and sufficient coolant should be used.
For such processing, the best material grade should be the coarse grain size and the PCD30M with the highest possible thermal stability. Efficient machining of bimetallic materials such as silicon-aluminum engine blocks is possible by combining sufficient coolant with the correct material grade at low cutting speeds.
In other existing bimetallic engines, the cylinder block is composed of an aluminum alloy (low Si content), and the cylinder liner is made of powder sintered material, or the cylinder liner is made of MMC material.
Carbon fiber composite material
With the goal of improving the power-to-weight ratio, a wide variety of synthetic materials have been developed by mixing fibers (carbon, glass, SiC, aromatic polyamine, etc.) in a matrix such as plastic, aluminum alloy, or titanium alloy. The fibers can be long or short and can be oriented or parallel. Each of these parameters will affect material properties and cutting characteristics.
The most common composite material for aerospace is CFRP (carbon fiber reinforced plastic), which is particularly effective for PCD tools. Machining should balance the risk of fiber flaking due to excessive feed rates and the risk of micro-collapse of the cutting edge due to excessive cutting speed.
Even if the sharp cutting edge is going through the soft core, the reinforcement of the carbon fiber will quickly passivate the cutting edge. It is more pronounced on fiberglass reinforced materials. A typical CFRP part is the wing of an aircraft. You can also find bearings, pump parts and sleeves made from this part material.
Titanium alloy
In the category of superalloys, titanium alloys generally exhibit superior mechanical and chemical properties at elevated temperatures, but are detrimental to processability. With PCD tools, you can use three times the cutting speed of carbide tools and calculate tool life in hours.
Plastic and reinforced plastic
The general feeling is that the processing of plastic materials is easy. However, soft plastics are not always very stable. If the correct cutting parameters are not applied, the machining process always generates heat, which may affect the size and material properties such as surface structure and color. PCD cutters are particularly effective for wear-resistant plastics (reinforced with carbon fiber (CF) and glass fiber (GF) for plastics).
graphite
Most of the processing of synthetic graphite is to produce electrodes. Although graphite is soft, it is very wear resistant. Even when the cutting speed reaches 1000m/min, the tool life of the PCD will still be invincible.
Copper and brass
When there is no alloying, this is a fairly easy to process material. When copper is strengthened with helium, it is necessary to reduce the cutting speed.
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, and 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 machining applications: low runout will prevent inconsistent load on the cutting edge
For PCD tools, the development of wear increases with the cutting speed until the cutting speed is higher than the turning point that causes the wear to rise rapidly. When the tool life is shortened, the cutting speed should be reduced. Tool life is largely independent of feed. High feed rates typically provide faster metal removal rates without shortening tool life as long as the cutting edge does not collapse. However, it should not exceed half the value of the tool nose radius. For cutting depths, Seco Tools recommends a maximum of 65% of the cutting edge length. The polished surface of the Secomax PCD insert means that coolant is not required. However, coolant can help you when there is built-up edge around the cutting edge or chip buildup.
Metal matrix composite
Metal matrix composites (MMC) are made of aluminum or titanium aluminum as the matrix, which is by far the most common matrix material. Addition to the matrix material is a ceramic reinforcing agent, most commonly in the form of granules, but occasionally more fibrous forms are more difficult to process. A range of ceramic materials are used for MMC, but the most common one is Si. According to the required wear resistance of the material, the added content is 15% to 40%.
In the following parts, these materials are gradually replacing heavy materials like cast iron: brake discs, engine blocks, pistons, cylinder liners.
When processing MMC, the cutting speed should be compatible with the ceramic content of the material. The higher the content of the ceramic reinforcing agent, the more wear resistant the workpiece is, so the cutting speed should be lower in order to protect the cutting edge. Positive angle cutting edges are generally accepted during aluminum alloy processing, but negative angle inserts provide a reinforced cutting edge for heavily reinforced materials.
Bimetal material
Processing two different materials that appear on one part is often a big challenge. One of the most common applications is face milling of silicon-aluminum materials with grey cast iron cylinder block engine blocks. Machining these bimetallic parts poses a challenge to the tool supplier, and the tool material that is handy when machining one of the metals is usually not very effective for the other metal. For face-to-face milling of silicon-aluminum engine blocks, the solution is to use a PCD.
When using PCD, you must consider the following conditions: PCD is the perfect cutting tool for machining aluminum alloys. It can be processed at very high cutting speeds while maintaining excellent tool life. Processing iron-based metal gray cast iron with PCD will result in rapid chemical wear. Chemical wear requires heat to develop it, so in order to minimize chemical wear on the PCD tool, the cutting speed should be reduced and sufficient coolant should be used.
For such processing, the best material grade should be the coarse grain size and the PCD30M with the highest possible thermal stability. Efficient machining of bimetallic materials such as silicon-aluminum engine blocks is possible by combining sufficient coolant with the correct material grade at low cutting speeds.
In other existing bimetallic engines, the cylinder block is composed of an aluminum alloy (low Si content), and the cylinder liner is made of powder sintered material, or the cylinder liner is made of MMC material.
Carbon fiber composite material
With the goal of improving the power-to-weight ratio, a wide variety of synthetic materials have been developed by mixing fibers (carbon, glass, SiC, aromatic polyamine, etc.) in a matrix such as plastic, aluminum alloy, or titanium alloy. The fibers can be long or short and can be oriented or parallel. Each of these parameters will affect material properties and cutting characteristics.
The most common composite material for aerospace is CFRP (carbon fiber reinforced plastic), which is particularly effective for PCD tools. Machining should balance the risk of fiber flaking due to excessive feed rates and the risk of micro-collapse of the cutting edge due to excessive cutting speed.
Even if the sharp cutting edge is going through the soft core, the reinforcement of the carbon fiber will quickly passivate the cutting edge. It is more pronounced on fiberglass reinforced materials. A typical CFRP part is the wing of an aircraft. You can also find bearings, pump parts and sleeves made from this part material.
Titanium alloy
In the category of superalloys, titanium alloys generally exhibit superior mechanical and chemical properties at elevated temperatures, but are detrimental to processability. With PCD tools, you can use three times the cutting speed of carbide tools and calculate tool life in hours.
Plastic and reinforced plastic
The general feeling is that the processing of plastic materials is easy. However, soft plastics are not always very stable. If the correct cutting parameters are not applied, the machining process always generates heat, which may affect the size and material properties such as surface structure and color. PCD cutters are particularly effective for wear-resistant plastics (reinforced with carbon fiber (CF) and glass fiber (GF) for plastics).
graphite
Most of the processing of synthetic graphite is to produce electrodes. Although graphite is soft, it is very wear resistant. Even when the cutting speed reaches 1000m/min, the tool life of the PCD will still be invincible.
Copper and brass
When there is no alloying, this is a fairly easy to process material. When copper is strengthened with helium, it is necessary to reduce the cutting speed.
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