Design Of Polycrystalline Diamond Cutters For Machining Of Workpieces

Design Of Polycrystalline Diamond Cutters For Machining Of Workpieces

Polycrystalline Diamond (PCD) cutters are used extensively in machining applications where high hardness, abrasive resistance, and thermal conductivity are required. These cutters consist of a tungsten carbide substrate on which a layer of synthetic diamond is deposited using high temperature and pressure techniques. PCD cutters are widely used for machining non-ferrous metals, fiber-reinforced plastics, and non-metallic materials. To design effective PCD cutters, several key criteria must be considered. Firstly, the diamond layer must be deposited evenly and firmly onto the substrate to provide maximum resistance to wear and thermal shock. The size, distribution, and orientation of the diamond particles must also be controlled precisely to ensure good cutting performance and tool life. Secondly, the PCD cutter must be designed to provide optimal chip evacuation and cooling during machining. This can be achieved by controlling the number, size, and shape of the cutting edges, as well as the geometry of the tool body. Additionally, sufficient coolant supply must be provided to avoid thermal damage to both the tool and the workpiece. Finally, the PCD cutter must be designed for ease of use and re-grinding. The tool body should be well balanced to minimize vibration and to ensure accurate cuts. Furthermore, the re-grinding process should be carefully carried out to maintain the integrity of the diamond layer and to ensure consistent cutting performance.

PCD cutters, synthetic diamond, tungsten carbide, chip evacuation, re-grinding

— Jacob Mitchell