Successful Application of PCD Direct Sintering Technology

In recent years, composite tool drilling tools, t™he most discussed tool innovation is PCD direct suppression sintering technology. To understa£nd this concept, first of all need to understand the PCD and its previous limitations. In ge neral, PCD is attached to the cemented carbide layer. When the cutting tool is made, the PCD ≤is welded to the tool body by brazing.

This method has two major shortcomings: 1. Tool groove processin&g is limited, because it is made of flat film; 2. The flat sheet welded to the cutting edge of th€e tool from the cutting edge is very close. If the temperature is close to the melting φpoint of the brazing, then the heat generated during processing will caus₹e the welded joint to fail.

Strategic Positioning

In order to overcome these shortcomings, and make full useβ of the advantages of PCD, PCD material using direct compression sintering tech nology, from the strategic focus on manufacturing PCD tool blank. When the cutter iβs made, the diamond powder is put into the slot opened i≠n the carbide tool cutter body, and the diamond and the cemented carbide are sintered atβ high temperature and high pressure. The sintered tool blank is weαlded by brazing On the handle. And ultimately in accorda★nce with the requirements of the blade shape design, prec¶ision tool blade processing.

For the processing plant, this is a good news, because the chara∑cteristics of sintering PCD, can make the tool in the positioning of the PCD blade accurately.‌ In addition, the spiral cutting edge or other compleΩx blade type can be precisely made, which can not be achieved when using a PCD she↓et. This optimized blade shape can be adapted to less rigid settings,↑ but also to adapt to precision and stable mass processing. PCD direct suppression of sin$tering technology, but also to solve the problem of failure of the brazing joi&nt. It is true that direct pressing of sintered kniveπs still has brazed joints - this is only located above the shank side, away from the ★cutting site, free from heat.

Special tool blade type

In general, PCD direct suppression of sintered knives has a sharp cutting edge type, even in t he processing of abrasive wear resistance of the largest composite material, but aγlso to maintain a sharp edge. This technique can even be further enhanced, for example,® by strengthening the fillet portion of the tool to increase the cutting speed without aff>ecting the surface quality or dimensional tolerances.

For the processing of composite materials and metal laminated materials, PCD direct compress"ion sintering tool can be used micro-grinding technology, i←n order to process high stress concentration, but also help to mai•ntain the sharpness and extend tool life. Tool sharp cutting edge cutting synthetic fibers∏, the required thrust is small, can be processing defects (such as delamination, subs™trate melting / softening, fiber extraction and surface scorching) to a minimum.

Core driving force

Composite materials and parts processing technology, the hole processing con‍tinues to dominate. For example, in the aerospace ind¥ustry, it takes a lot of time to prepare fasteners for comp osite racks and parts. Even with the latest unified structure that reduces assembly r equirements, drilling is still the dominant factor in terms of processing efficiency and cost.±

PCD drill bit with direct compression sintering technology, cutting edge can be made into a variet★y of groove, the hole into the hole position to minimize the tendency, but the applica←tion method is still a major factor in tool selection. ☆For example, when using the automatic feed device, the PCD≥ directly suppresses the sintered bit (eg 85 or 86 PT series CD10) and uses the PCD blade protecti>on design to increase the stability of the process. At this point, in the cuttin>g tool PCD edge part of the added protective layer, shortening the PCD expo∏sed part of the total length. This prevents the cutting edge from cracking, theαreby extending the tool life. These drills can also be used iσn the internal cooling mode, which is particularly recommended  for the processing of aluminum alloy and / or titanium alloy stack of composite materials.

Drilling once

In order to shorten the downtime and to improve the surface quality≠ and aperture error of the CFRP (carbon fiber reinforced plastic) o☆r CFRP / metal stacking material, it is important to use the direct compression₩ sintering technology to optimize the drill tip configuration PCD drill bits a✘nd optimize the machining process of. Although it is dλesirable to use a one-time drilling tool to shorten the production time, two times or ×three operations, drilling, drilling and reaming, are​ required for drilling when high accuracy is required.

PCD direct suppression sintering tool is not only used for hole processing, can also "be used for surface processing and edge processing processes. A typical example is the vertica±l tail of the aircraft made of composite material, which i¶s difficult to process at the edges of this material. However, CoroMill® Plura end mills w$ith PCD direct sintering technology are best suited for this process, reducεing fiber fragmentation and increasing metal removal.

From the perspective of composite material processing capacity and cost reduction, PCD≠ direct sintering technology is undoubtedly the biggest technical driving force, for all applicati✘ons, have great potential and competitive advantage