PCD tool manufacturing process comprises two main stages:

1. manufacturing PCD composite sheet: PCD composite sheet is made ​​of natural or synthetic diamond powder and the binding agent (which contains cobalt, nickel and other metals) by a certain percentage at a high temperature (1000 ~ 2000 ℃), pressure (5 to 100,000 atmospheres) sintering. In the sintering process, the binding agent is added, so that a diamond crystal is formed in between the TiC, SiC, Fe, Co, Ni as the main component is combined with the bridge, the diamond crystals are embedded in the form of covalently binding the bridge skeleton. The disk is typically made ​​of a composite sheet of a fixed diameter and thickness, the need for the sintered composite sheet for polishing and other appropriate physical and chemical treatment. 
2. PCD inserts for machining: PCD inserts for machining composite sheet including cutting, welding blade, blade sharpening steps. (all Sundi Precision Tools'S pcd import form E6 UK or GE US)

PCD cutting process of the composite sheet

Since PCD composite film with high hardness and wear resistance, it is necessary to adopt a special processing technology. Currently, the main use of the composite sheet machining PCD EDM wire cutting, laser machining, ultrasonic machining, high-pressure water jet technology and so are several methods to compare the characteristics of the process is as follows:

PCD composite sheet cutting process comparison:

process methods - process features!

EDM - highly concentrated pulse discharge energy, a powerful explosive discharge of the material so that the metal melt PCD, 2,3 partial oxidation of diamond and graphite, some diamond shedding, good technology, high efficiency


ultrasonic processing - processing efficiency is low, diamond powder consumption, large dust pollution


laser processing - non-contact processing, high efficiency, small deformation processing, technology and poor


In the processing method, EDM was better. PCD in the presence of a combination of the bridge makes it possible EDM composite sheet. In the working fluid conditions, using a pulse voltage to the electrode near the metal working fluid is formed at the discharge channel, and the locally generated sparks, polycrystalline diamond instantaneous high temperature can melt and fall off, thereby forming the desired triangular, rectangular, or square head blank. Efficiency and surface quality EDM affected PCD composite sheet cutting, PCD grain size, thickness and electrode quality and other factors, of which a reasonable choice of cutting speed is critical, experiments show that increasing the cutting speed will reduce the surface quality, The cutting speed is too low will produce "arch wire" phenomenon, and reduce cutting efficiency. PCD will be reduced to increase the thickness of the blade cutting speed


PCD inserts welding
PCD composite sheet and the binding mode of the tool body in addition to using mechanical clamping and bonding methods, mostly by way of the brazing sheet pressed composite PCD carbide substrate. Welding methods include laser welding, vacuum diffusion welding, vacuum brazing, high frequency induction brazing. Currently, low investment, low-cost high-frequency induction heating is widely used in brazing welding PCD inserts. In the blade welding process, welding temperature, flux and solder alloy choice will directly affect the performance after welding tool. In the welding process, the welding temperature control is very important, such as welding temperature is too low, the welding strength is insufficient; such as welding temperature, PCD easily graphitized, and may lead to "burnt", affecting PCD and carbide composite sheet binding matrix. In the actual processing, according to the holding time and the degree of difficulty to red PCD control the welding temperature (generally less than 700 ℃).


PCD blade sharpening process
PCD so high hardness material removal rate is very low (even only carbide removal of parts per million). Currently, PCD tool sharpening process mainly uses resin bonded diamond grinding wheel. Due to the abrasive grinding wheel and PCD is the interaction between the material hardness similar between the two, so the grinding law more complicated. For high granularity, low-speed wheel, using a water-soluble coolant can improve grinding efficiency and precision grinding of PCD. Select agents should be considered in conjunction wheel grinder type and processing conditions. Since almost not affected by the hardness of the workpiece grinding technology EDG (EDG), so using EDG grinding PCD technology has great advantages. Some complex shapes PCD tools (such as woodworking tools) are also on this flexible grinding grinding process has huge demand. With the continuous development of EDM grinding technology, EDG technology will become a major development direction of PCD grinding.