Summary: Compound to diamond thick film and PCD piece microstructure undertook contrasting analytic, with the diamond thick film that optimizes a design and PCD Duan Xi the knife undertook cutting experiments, proof diamond thick film carries milling cutter to be able to come true " with mill era is ground " treatment of face of lens exceeding essence of life. The tall hardness of cutting tool of 1 foreword diamond and other actor opposite sex can make its suit machine the nonferrous metal material such as silicon alloy, aluminium alloy, copper alloy and fiber to enhance the colophony of composite material, phenolic aldehyde, metalloid material such as black lead very much. Natural diamond material because lesser, price machines grain costlily, not easily wait for a reason, its popularize application to be restricted certainly. Man-made gets together brilliant diamond (although PCD) cutting tool is producing main effect in domain of semifinishing machining, finish machining, but as a result of bit appearance the onefold, limitation that does not have bits chamfer and geometrical parameter, its actor or actress different function is developed adequately hard. Cutting tool of diamond thick film is the new-style cutting tool that will deposit diamond thick film solders to be made on hard alloy razor blade, have superior treatment performance and higher performance/price ratio. The research that our country carries milling cutter to diamond thick film, development and application still are in at present start level. The microstructure that the article carries milling cutter to diamond thick film, design and preparation and the application in superfinishing undertook experimenting study. The microstructure analysis of 2 diamond thick film is the treatment performance that studies cutting tool of diamond thick film, produce diamond thick film and entrance PCD to the country with lens of JSOM35C scanning report compound piece microstructure undertook contrasting checking an analysis, the microstructure image of two kinds of material is like a graph respectively 1, the graph is shown 2 times. Graph 1 PCD is compound piece microstructure pursues the microstructure of 2 diamond thick film by the graph 1 knowable, PCD is compound piece microstructure gets together for grain shape brilliant organization, put in more space, contain a lot of acicular black lead body; Because minim binder was added in the preparation process of high temperature high pressure, accordingly its hardness is affected certainly (HK5000 ～ 8000) , under the hardness of natural diamond, but its combat impact strength taller; With PCD compound a cutting tool that makes appear on point a lot of rough those who rectify is small toothed, because this applies to semifinishing machining and finish machining, but the superfinishing that does not suit to ask to achieve precision of appearance of lens side stage. By the graph 2 knowable, the microstructure of diamond thick film is complete and onefold, space is little and subtle, with likeness of single crystal diamond; Because material organization is comprised completely by diamond, without binder be mingled with, because this has taller hardness (HK8300) , approximate the average hardness cost of natural diamond; If choose proper blade to grind craft, cutting tool of diamond thick film can be obtained without toothed linear state edge, suit the superfinishing of precision of appearance of lens side stage very. The design of 3 upright milling cutter and preparation experiment to undertake comparative cutting, mix with diamond thick film respectively PCD is compound piece preparation becomes the Duan Xi knife that has same figure and geometrical parameter. The upright milling cutter that chooses via actor designs parameter to be: Diametical Ø125mm, tooth number is 6 tine, cut deep before horn 8 ° of 3 ° ～ , the horn before radial 0 ° ～ - 5 ° , tool cutting edge angle 75 ° ; Hard alloy matrix uses YG3X square bit, cutter hub is used type can be pressed before dislocation, dimension of cutter hub ply, aperture, join design by national level. Part with laser PCD compound piece it is triangular flake with cut of diamond thick film, become grinding of razor blade of YG3X hard alloy the knife chamfer that agrees with triangular diaphragm dimension with special tool, use in order to have when drill rod solder. Very tall interface is had between diamond thick film and general metal and its alloy can, be infiltrated by place of general alloy of low melting point hard, and solderability of diamond thick film is poorer. To raise the solderability between diamond thick film and hard alloy matrix, used solder of tailor-made high strenth silver-colored copper alloy, use craft of solder of drill rod of hard alloy low temperature to solder razor blade of diamond thick film and PCD razor blade. Have the bit with drill rod good solder is the same as level surface the blade of precision is ground respectively, the diamond emery wheel of high strenth, thick granuality is chosen when half essence blade is ground, the diamond emery wheel of fine granuality is chosen when blade of essence of life is ground, circular arc of cutting tool point of a knife uses tool automatic blade is ground. Classics of the knife that carry mill is assembled, after debugging, its axial and radial round jumpy control are in 0. Inside 002mm limits. 4 cutting experiment machines a machine tool: BI-266 CNC Milling; Measure an instrument: Measuring instrument of M4P surface surface roughness; Workpiece material: LY12 aluminium alloy; Cutting means: Do cutting. Use diamond thick film to carry milling cutter and PCD Duan Xi to Dao Xi cuts LY12 aluminium alloy and undertake metrical to surface roughness of test specimen surface respectively below identical cutting dosage. Test result sees next tables. The graph shows the milling process that carries milling cutter for diamond thick film 3 times; The graph shows what the external form that carries milling cutter for diamond thick film and treatment go out 4 times to exceed workpiece of face of lens of essence of life. After milling machines an end, 6 tooth that carry milling cutter and sword of PCD Duan Xi to diamond thick film with 100 times microscope undertook checking, discover every tooth is passed 6000 for many times cutting pounds load (6 tooth bear 36000 times to pound in all) hind, tooth all happens without collapse blade phenomenon. Test result proves, the cutting tool of diamond thick film that uses figure of geometry of reasonable knife head has PCD to carry the advantage of milling cutter not only, and the superfinishing that can realize old plane. Dosage of cutting of workpiece of cutting tool of test result of contrast of knife of Duan Xi of watch diamond thick film and knife of PCD Duan Xi speed of cutting of Ra(µm) of workpiece surface surface roughness (M/min) is cut deep (Mm) feed (Mm/r) diamond thick film carries aluminium alloy of milling cutter LY12 1570.
020.
020.
10PCD carries aluminium alloy of milling cutter LY12 1570.
020.
020.
40 graphs the milling process that 3 diamond thick film carry milling cutter pursues thick film of 32 tine diamond carries the 6 ～ that my plant design produces the work of face of lens exceeding essence of life that 4 diamond thick film carries milling cutter and treatment milling cutter already applied at, came true " with mill era is ground " superfinishing of efficient, high quality. The microstructure of material of thick film of 5 conclusion diamond and diamond of natural single crystal are similar. Cutting tool of diamond thick film applies to treatment of cutting exceeding essence of life, can replace cutting tool of costly diamond of natural single crystal partly. The diamond thick film with geometrical appearance and parameter reasonable design carries what mill Dao Kecheng gets cutting load to be pounded repeatedly, the old plane that solves nonferrous metal and its alloy material effectively, transcend difficult problem of big planar superfinishing, material of milling treatment nonferrous metal can achieve the treatment result of lens face precision when great planar work. Diamond thick film carries milling cutter not only applicable at nicety treatment machine tool, also applicable at average milling machine, can achieve better treatment beneficial result, have promotion application value. CNC Milling
CNC Machining