In the processing of modern engineering materials, there are more requirements for the application of materials and new materials, such as higher requirements for material hardness, and superhard materials naturally have many requirements for CNC machining tools. Ordinary tools are difficult to achieve this requirement, so superhard tools came into being.
Superhard tools mainly refer to pcd tools, cbn tools, etc. Different tools also have different characteristics and process different materials. So what is the difference between superhard knives such as PCD/CBN ceramics? What materials can be processed?
1. PCD tool
The pcd tool is artificial polycrystalline diamond, which is made of natural or synthetic diamond powder and binder (including cobalt, nickel and other metals) in a certain proportion under high temperature (1000 ~ 2000 °C) and high pressure (5 ~ 100,000 atmospheres). It is sintered to form a PCD composite sheet with a fixed diameter and thickness, and then through cutting, welding, sharpening and other processes to make a PCD tool.
Usually, the layer thickness of PCD composite sheet is about 0.3-1.0mm, which can be made into PCD milling cutter, PCD insert, PCD turning tool, PCD reamer, PCD drill, and various non-standard custom tools, etc. Since the diamond powder will dissolve in iron when PCD is above 800 degrees Celsius, it cannot process iron-containing materials. PCD tool processing material:
Non-ferrous metals and their alloys - such as aluminum, copper, gold, silver and their alloys, die-casting aluminum, red copper, cemented carbide, etc. For die-casting aluminum parts, CDW085 and CDW002 materials are commonly used, and the processing finish and brightness are better.
Composite materials - such as graphite, carbon fiber composite materials, glass fiber composite materials, aluminum-based silicon carbide, glass fiber reinforced plastic, metal-based composite materials, etc. For composite materials, CDW302 and CDW010 materials are commonly used, which have good durability and long life.
Other non-metal difficult-to-machine materials, such as ceramics, engineering plastics, hard rubber products, semiconductor materials, etc.
2. CBN tools
CBN (cubic boron nitride) is a material whose hardness is second only to diamond (diamond). , is a new type of inorganic superhard material, which has been widely used in the processing fields of different industries.
CBN tool processing material:
High-hardness cast iron—such as high-chromium cast iron, alloy cast iron, nickel-hard cast iron, and white cast iron are all high-hardness cast irons. Typical parts include rollers, industrial pumps, etc. For high hardness cast iron, the commonly used BN-K1 material has significant advantages.
High hardness steel parts - such as high manganese steel, high speed steel, hardened steel, etc. Typical parts include rolling mill walls, high speed steel rolls, hardened gears/gear shafts, bearings, ball screws, molds, etc.
Gray cast iron (HT150/200/250/300, etc.) - such as engine block/cylinder head, brake disc, brake drum, pulley, clutch pressure plate, etc. are all gray iron castings.
Other difficult-to-machine materials, such as powder metallurgy, superalloy materials, and nickel-based, iron-based, cobalt-based and other high-hardness surfacing/spray welding/laser cladding/thermal spraying material workpieces.
PCD tools and CBN tools have similarities and can be used for high-speed cutting. In the automotive field, the automotive industry is one of the important pillars of the national economy, and it is also the best application field for PCBN tools and PCD tools. After quenching, gears and bearings , automotive wheel bearing units, cylinder liners, ball cage universal joints, various shaft parts, synchronizer gear hubs, wear rings, etc., aluminum alloy engine cylinder blocks, cylinder liners, pistons, hubs, gearboxes, etc. Using CBN tools and PCD tools, and using high-speed CNC machine tools, the processing time can be greatly shortened and the processing efficiency can be improved. The combination of CBN tools and PCD tools is invincible.