Price changes In the past, high prices have been a major obstacle to the widespread acceptance of PCD (polycrystalline diamond) tools, but the situation has changed a lot. The industry estimates that in the past two or three years, the price of PCD tools has dropped by 40% to 60%. One of the reasons for the "diving" of PCD tool prices is that the market supply exceeds demand. In the early 1990s, the development of PCD tools began to outpace traditional carbide tools, and the market demand for PCD tools continued to increase over the next decade. However, with the maturity of PCD tool manufacturing technology, its sales growth momentum began to slow down. In addition, new competitors entering the PCD tool manufacturing industry have also shaken the original market price system. Another reason for the decline in PCD tool prices is the ever-decreasing tool manufacturing costs, and tool manufacturing processes such as EDM for diamond roughing and precision machining of cutting edges continue to improve. In addition, the quality of diamond grinding wheels for processing PCD tools is significantly improved and the cost is greatly reduced compared to a decade ago. China's demand for PCD tools is increasing.
Tool Features The machining of aluminum workpieces with PCD tools has the advantages of long tool life and high metal removal rate. The disadvantages are expensive tools and high processing costs. This has formed a consensus in the machinery manufacturing industry. However, in recent years, many changes have taken place in the development and application of PCD tools. Today's aluminum materials are no longer the same in performance. When processing various newly developed aluminum alloy materials (especially high silicon content composite materials), in order to optimize productivity and processing quality, we must carefully select PCD tools. Grades and geometric parameters to suit different processing requirements. Another change in PCD tools is the continuous reduction in processing costs. The price of PCD tools has dropped by more than 50% due to the combination of market competition pressure and tool manufacturing process improvements. The above trends have led to the increasing use of PCD tools in the processing of aluminum materials, and the suitability of tools is limited by the materials being processed.
Correct use When machining aluminum alloy materials, the roughing cutting speed of cemented carbide tools is about 120m/min, and the cutting speed of PCD cutters can reach about 360m/min even when roughing high-silicon aluminum alloy. Tool manufacturers recommend the use of fine-grained (or medium-grain) PCD grades to process silicon-free and low-silicon aluminum alloy materials. High silicon aluminum alloy material is processed by coarse particle PCD grade. If the surface finish of the milled workpiece is not satisfactory, the surface of the workpiece can be polished with a thin-grained blade to obtain a satisfactory surface finish.
The correct application of PCD tools is a prerequisite for satisfactory machining results. Although the specific causes of tool failure are different, they are usually caused by incorrect use of objects or methods of use. When ordering a PCD tool, the user should correctly grasp the adaptability range of the tool. For example, when machining a ferrous metal workpiece (such as stainless steel) with a PCD tool, the diamond is easily chemically reacted with the carbon in the steel, which will cause the PCD tool to wear rapidly. Therefore, the correct choice for processing the hardened steel should be a PCBN tool.
In general, in order to reduce the cutting force and prevent the formation of built-up edge, the PCD tool should adopt a positive cutting angle. However, when processing high silicon aluminum alloys (especially when using PCD tools instead of carbide tools), the back angle of the PCD tool is preferably slightly smaller than the back angle (eg 250) used by the original cemented carbide tool. Improve the cutting performance of PCD tool cutting edge on high silicon aluminum alloy. The positive rake angle of the PCD tool should not be too large, because the larger the rake angle of the tool, the lower the cutting edge strength. In Other words, the smaller the back angle of the PCD tool, the higher the strength of the cutting edge. In order to maximize the cutting edge strength while ensuring that the tool has a positive cutting angle, a US company will weld a CNMX blade with a negative rake angle to the PCD tool tip and form a positive cutting angle so that the negative rake angle of the blade Provides high cutting edge strength without affecting normal tool cutting. When the cutting edge of the PCD tool is prepared, there is no need to do excessive processing on the diamond tip. For the PCD milling cutter, the cutting edge can be slightly sharpened. In addition, the certain axial inclination of the cutting edge can also help to improve the PCD tool. Cutting performance.
The successful application of PCD inserts depends not only on the rational selection of tool geometry and cutting parameters, but also on the tool supplier's solution to the problems encountered in tool use. For example, a large auto parts shop uses the PCD inserts supplied by J&M Diamond Tools for slot milling. Originally, each PCD diamond insert can process 1,500 parts, but the chips generated by the machining will damage the surface of the part. For this reason, J&M proposed The EDM (Electrical Discharge Machining) process was used to machine a radial chipbreaker solution on the top of the diamond blade, and 50 blades were specially customized to solve this problem. The number of parts processed per PCD blade has now increased from 1,500 to 4,300.
Tool Features The machining of aluminum workpieces with PCD tools has the advantages of long tool life and high metal removal rate. The disadvantages are expensive tools and high processing costs. This has formed a consensus in the machinery manufacturing industry. However, in recent years, many changes have taken place in the development and application of PCD tools. Today's aluminum materials are no longer the same in performance. When processing various newly developed aluminum alloy materials (especially high silicon content composite materials), in order to optimize productivity and processing quality, we must carefully select PCD tools. Grades and geometric parameters to suit different processing requirements. Another change in PCD tools is the continuous reduction in processing costs. The price of PCD tools has dropped by more than 50% due to the combination of market competition pressure and tool manufacturing process improvements. The above trends have led to the increasing use of PCD tools in the processing of aluminum materials, and the suitability of tools is limited by the materials being processed.
Correct use When machining aluminum alloy materials, the roughing cutting speed of cemented carbide tools is about 120m/min, and the cutting speed of PCD cutters can reach about 360m/min even when roughing high-silicon aluminum alloy. Tool manufacturers recommend the use of fine-grained (or medium-grain) PCD grades to process silicon-free and low-silicon aluminum alloy materials. High silicon aluminum alloy material is processed by coarse particle PCD grade. If the surface finish of the milled workpiece is not satisfactory, the surface of the workpiece can be polished with a thin-grained blade to obtain a satisfactory surface finish.
The correct application of PCD tools is a prerequisite for satisfactory machining results. Although the specific causes of tool failure are different, they are usually caused by incorrect use of objects or methods of use. When ordering a PCD tool, the user should correctly grasp the adaptability range of the tool. For example, when machining a ferrous metal workpiece (such as stainless steel) with a PCD tool, the diamond is easily chemically reacted with the carbon in the steel, which will cause the PCD tool to wear rapidly. Therefore, the correct choice for processing the hardened steel should be a PCBN tool.
In general, in order to reduce the cutting force and prevent the formation of built-up edge, the PCD tool should adopt a positive cutting angle. However, when processing high silicon aluminum alloys (especially when using PCD tools instead of carbide tools), the back angle of the PCD tool is preferably slightly smaller than the back angle (eg 250) used by the original cemented carbide tool. Improve the cutting performance of PCD tool cutting edge on high silicon aluminum alloy. The positive rake angle of the PCD tool should not be too large, because the larger the rake angle of the tool, the lower the cutting edge strength. In Other words, the smaller the back angle of the PCD tool, the higher the strength of the cutting edge. In order to maximize the cutting edge strength while ensuring that the tool has a positive cutting angle, a US company will weld a CNMX blade with a negative rake angle to the PCD tool tip and form a positive cutting angle so that the negative rake angle of the blade Provides high cutting edge strength without affecting normal tool cutting. When the cutting edge of the PCD tool is prepared, there is no need to do excessive processing on the diamond tip. For the PCD milling cutter, the cutting edge can be slightly sharpened. In addition, the certain axial inclination of the cutting edge can also help to improve the PCD tool. Cutting performance.
The successful application of PCD inserts depends not only on the rational selection of tool geometry and cutting parameters, but also on the tool supplier's solution to the problems encountered in tool use. For example, a large auto parts shop uses the PCD inserts supplied by J&M Diamond Tools for slot milling. Originally, each PCD diamond insert can process 1,500 parts, but the chips generated by the machining will damage the surface of the part. For this reason, J&M proposed The EDM (Electrical Discharge Machining) process was used to machine a radial chipbreaker solution on the top of the diamond blade, and 50 blades were specially customized to solve this problem. The number of parts processed per PCD blade has now increased from 1,500 to 4,300.
County Shengxin Metal Products Co., Limited , http://www.hbwire-mesh.com