Saint-Gobain

Layla Harrison

Diamond tools, with low friction and high hardness, tackle non-ferrous metals and non-metallic materials, advancing precision machining and manufacturing.

Diamond tools have emerged as indispensable assets in material processing, particularly when dealing with challenging non-ferrous metals and non-metallic materials. Traditional tools often face challenges when it comes to non-ferrous metals like copper, zinc, and aluminum, as these materials tend to adhere to the tool during processing.

Diamond tools, owing to their low friction coefficient and low affinity with non-ferrous metals, provide a solution by preventing material adhesion. The large elastic modulus of the diamond ensures minimal deformation of the cutting edge and facilitates the completion of cutting processes with better surface quality. Similarly, non-metallic materials with high hardness, such as glass fiber-reinforced plastic, silicon, and hard carbon fiber/epoxy resin composites, pose difficulties for conventional tools. Diamond tools, with their high hardness, excellent wear resistance, and precision, prove highly effective in machining these challenging materials, resulting in high efficiency.

Within ultra-precision machining, diamond tools have become instrumental. Modern technologies are advancing manufacturing towards enhanced precision. Diamond, with its low friction, minimal thermal expansion, and high thermal conductivity, emerges as an ideal choice in this pursuit of precision. The ability to produce thin chips, facilitate chip flow, and resist the development of heat-induced issues positions diamond tools as key players in achieving ultra-precision machining with minimal cutting deformation and high-quality surface finishes.

Several methods are employed in the creation of diamond tools. Thin-film coated tools, produced through chemical vapor deposition (CVD) of diamond films on materials like SiN4 ceramics and WC+Co cemented carbide, offer versatility for various cutting tool geometries. While these tools provide excellent cutting capabilities, their poor adhesion with the matrix and lack of regrinding properties are notable drawbacks.

Thick-film diamond welding tools address these limitations effectively. These tools are created by preparing large-area diamond films, cutting them into desired shapes, welding them onto tool base materials, and grinding and polishing for enhanced adhesion. Techniques such as DC plasma jet CVD are employed to prepare thick diamond films, and innovations like laser cutting contribute to shaping these tools efficiently.

Diamond sintering tools involve using a thick diamond film roll grinding or direct application of high-temperature and high-pressure methods to create diamond-sintered bodies on WC–Co alloys. These tools exhibit high wear resistance, catering to specific machining needs. Single-crystal diamond tools involve fixing a diamond monocrystal onto a knife head using various methods, including mechanical reinforcement, powder metallurgy, and bonding. Despite their effectiveness, challenges such as differences in thermal expansion coefficients leading to diamond detachment persist.

The use of diamond tools in material processing has brought about transformative advancements. From addressing challenges with non-ferrous metals to excelling in machining non-metallic materials, these tools continue to evolve. The ongoing quest for precision machining and the development of innovative diamond tooling methods indicate a promising future for these tools in modern manufacturing. As the industry continues to tackle challenges and make breakthroughs, diamond tools are poised to play a pivotal role in shaping the landscape of material processing.