Diamond materials that can be made into cutting tools include natural single crystal diamond, artificial single crystal diamond, chemical vapor deposition (CVD) diamond thick film, artificial polycrystalline diamond compact, and the like.
1. Natural single crystal diamond Natural single crystal diamond is an anisotropic single crystal. With a hardness of HV9000-10000, it is the hardest material in nature. The wear resistance of this material is excellent, the tool can be made to maintain dimensional stability for a long time during cutting, and therefore has a long tool life.
The natural diamond cutter edge can be machined extremely sharply. Can be used to make ophthalmic and neurosurgical scalpels; can be used to process curved surfaces of contact lenses; can be used to cut light-guided glass fibers; used to process gold and platinum jewelry patterns; the most important use is high-speed ultra-finishing non-ferrous metals and their alloys. Such as aluminum, gold, babbitt, beryllium copper, copper and so on. Ultra-precision machining tools made with natural diamonds have a circular arc at the tip of the knife and are observed under a 400x microscope without any defects. They are used for processing aluminum alloy polyhedral mirrors, oxygen-free copper laser mirrors, gyroscopes, and video recorder drums. The roughness can reach Ra (0.01-0.025) μm.
The natural diamond material has poor toughness and low bending strength, only (0.2-0.5) Gpa. The thermal stability is poor, and the hardness will be lost when the temperature reaches 700°C-800°C. When the temperature is higher, it will be carbonized. In addition, it has a strong affinity with iron and is generally not suitable for processing steel.
2. Artificial single crystal diamond Artificial single crystal diamond is used as a cutting tool material, and there is currently an industrial grade single crystal diamond material produced by DE-BEERS available on the market. This material is slightly less rigid than natural diamond. Other properties are comparable to natural diamonds. Due to the artificial manufacture, its cleavage direction and size become controllable and uniform. With the development of high-temperature and high-pressure technology, the maximum size of synthetic single crystal diamond can already reach 8mm. Due to the relatively good consistency and lower price of this material, it has received extensive attention. As a new material to replace natural diamond, the application of artificial single crystal diamond will have great development.
3. Artificial polycrystalline diamond Artificial polycrystalline diamond (PCD) is a polycrystalline material obtained by solvent polymerization of diamond micropowder under high temperature and high pressure. Under normal circumstances made of carbide as the base of the overall round piece, called polycrystalline diamond compact. According to the thickness of the diamond matrix, the composite sheet has different specifications such as 1.6mm, 3.2mm, 4.8mm and so on. The thickness of polycrystalline diamond is generally about 0.5mm. At present, the diameter of domestically produced PCD has reached 19mm, while foreign companies such as GE's largest composite sheet have already achieved 58mm in diameter, and De Beers has reached 74mm.
According to the need of making tools, laser or wire cutting can be used to cut the cutter heads of different sizes and angles to make lathes, boring cutters, and milling cutters.
The hardness of PCD is lower than that of natural diamond (around HV6000), but its bending strength is much higher than that of natural diamond. In addition, by adjusting the particle size and concentration of the diamond powder, the mechanical and physical properties of the PCD product are changed to meet the needs of different materials and different processing environments, providing a variety of choices for tool users.
PCD cutters have a much higher impact and shock resistance than natural diamonds. Compared with cemented carbide, the hardness is 3-4 times higher; the wear resistance and life is 50-100 times higher; the cutting speed can be increased by 5-20 times; the roughness can reach Ra0.05 μm. High cutting efficiency and stable machining accuracy.
PCD, like natural diamond, is not suitable for processing steel and cast iron. This tool is mainly used to process non-ferrous metals and non-metallic materials, such as: aluminum, copper, zinc, gold, silver, platinum and its alloys, as well as ceramics, carbon fiber, rubber, plastics and so on. Another major function of PCD is the processing of wood and stone.
PCD cutters are particularly suitable for machining high-silicon aluminum alloys and are therefore widely used in the automotive, aerospace, electronics and marine industries.
4, CVD diamond film CVD diamond thick film is a chemical vapor deposition method of diamond material. As a tool material its hardness is higher than PCD. Because it contains no metal binder, it has high thermal conductivity and high temperature oxidation resistance. However, the CVD material currently produced has relatively poor toughness, and it cannot be cut and processed by a wire cutting method, and its use has been limited. Due to the lack of cutting directionality, the grinding process is poor, making it extremely difficult to grind as sharp edges as natural diamond and artificial single crystal diamond. The use as a cutting tool is still in the experimental stage, pending further research and development.
1. Natural single crystal diamond Natural single crystal diamond is an anisotropic single crystal. With a hardness of HV9000-10000, it is the hardest material in nature. The wear resistance of this material is excellent, the tool can be made to maintain dimensional stability for a long time during cutting, and therefore has a long tool life.
The natural diamond cutter edge can be machined extremely sharply. Can be used to make ophthalmic and neurosurgical scalpels; can be used to process curved surfaces of contact lenses; can be used to cut light-guided glass fibers; used to process gold and platinum jewelry patterns; the most important use is high-speed ultra-finishing non-ferrous metals and their alloys. Such as aluminum, gold, babbitt, beryllium copper, copper and so on. Ultra-precision machining tools made with natural diamonds have a circular arc at the tip of the knife and are observed under a 400x microscope without any defects. They are used for processing aluminum alloy polyhedral mirrors, oxygen-free copper laser mirrors, gyroscopes, and video recorder drums. The roughness can reach Ra (0.01-0.025) μm.
The natural diamond material has poor toughness and low bending strength, only (0.2-0.5) Gpa. The thermal stability is poor, and the hardness will be lost when the temperature reaches 700°C-800°C. When the temperature is higher, it will be carbonized. In addition, it has a strong affinity with iron and is generally not suitable for processing steel.
2. Artificial single crystal diamond Artificial single crystal diamond is used as a cutting tool material, and there is currently an industrial grade single crystal diamond material produced by DE-BEERS available on the market. This material is slightly less rigid than natural diamond. Other properties are comparable to natural diamonds. Due to the artificial manufacture, its cleavage direction and size become controllable and uniform. With the development of high-temperature and high-pressure technology, the maximum size of synthetic single crystal diamond can already reach 8mm. Due to the relatively good consistency and lower price of this material, it has received extensive attention. As a new material to replace natural diamond, the application of artificial single crystal diamond will have great development.
3. Artificial polycrystalline diamond Artificial polycrystalline diamond (PCD) is a polycrystalline material obtained by solvent polymerization of diamond micropowder under high temperature and high pressure. Under normal circumstances made of carbide as the base of the overall round piece, called polycrystalline diamond compact. According to the thickness of the diamond matrix, the composite sheet has different specifications such as 1.6mm, 3.2mm, 4.8mm and so on. The thickness of polycrystalline diamond is generally about 0.5mm. At present, the diameter of domestically produced PCD has reached 19mm, while foreign companies such as GE's largest composite sheet have already achieved 58mm in diameter, and De Beers has reached 74mm.
According to the need of making tools, laser or wire cutting can be used to cut the cutter heads of different sizes and angles to make lathes, boring cutters, and milling cutters.
The hardness of PCD is lower than that of natural diamond (around HV6000), but its bending strength is much higher than that of natural diamond. In addition, by adjusting the particle size and concentration of the diamond powder, the mechanical and physical properties of the PCD product are changed to meet the needs of different materials and different processing environments, providing a variety of choices for tool users.
PCD cutters have a much higher impact and shock resistance than natural diamonds. Compared with cemented carbide, the hardness is 3-4 times higher; the wear resistance and life is 50-100 times higher; the cutting speed can be increased by 5-20 times; the roughness can reach Ra0.05 μm. High cutting efficiency and stable machining accuracy.
PCD, like natural diamond, is not suitable for processing steel and cast iron. This tool is mainly used to process non-ferrous metals and non-metallic materials, such as: aluminum, copper, zinc, gold, silver, platinum and its alloys, as well as ceramics, carbon fiber, rubber, plastics and so on. Another major function of PCD is the processing of wood and stone.
PCD cutters are particularly suitable for machining high-silicon aluminum alloys and are therefore widely used in the automotive, aerospace, electronics and marine industries.
4, CVD diamond film CVD diamond thick film is a chemical vapor deposition method of diamond material. As a tool material its hardness is higher than PCD. Because it contains no metal binder, it has high thermal conductivity and high temperature oxidation resistance. However, the CVD material currently produced has relatively poor toughness, and it cannot be cut and processed by a wire cutting method, and its use has been limited. Due to the lack of cutting directionality, the grinding process is poor, making it extremely difficult to grind as sharp edges as natural diamond and artificial single crystal diamond. The use as a cutting tool is still in the experimental stage, pending further research and development.
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