Diamond-coated tools are primarily used for machining non-ferrous materials such as aluminium-silicon alloys, copper alloys, fibre-reinforced polymers, green ceramics, and graphite. These tools are coated with CVD diamonds, which strengthen the cutting tool equipment and reduce friction during use. The diamond coating also helps maintain the sharpness of the cutting edge over time.
Diamond-coated tools have several advantages. Diamond is the hardest known material and is extremely abrasion resistant, making it ideal for cutting applications. The high thermal conductivity of diamond helps remove damaging heat from the cutting edge, preventing damage to heat-sensitive workpiece materials. Additionally, diamond has a low coefficient of friction, which aids in material flow up the flutes of the coated tools.
The CVD diamond-coating process allows for the growth of a wide range of surface structures, which can be optimized for specific applications. For example, when tool edge sharpness is crucial, the diamond film can be grown thin and smooth. Thicker films are needed when abrasion is the main wear mechanism. Growing a faceted surface has been shown to reduce cutting forces and increase tool lifetime.
Most types of tools that can be ground in the correct grade of carbide can be diamond coated. However, it is usually more cost-effective to diamond-coat tools with a diameter between 0.008" (0.20mm) and 0.500" (12.70mm). Larger diameters can be coated, but insert tooling is often used for these sizes. Many tool companies stock diamond-coated cutting tools or can manufacture them for customers.
There are two common forms of diamond in cutting tools: micron-sized grains dispersed in a metal matrix (usually cobalt) sintered onto the tool, known as polycrystalline diamond (PCD), and diamond coatings. PCD-tipped tools are commonly used in mining and cutting applications. The coating technology involves chemical vapour deposition (CVD) of microcrystalline diamond layers with sharp edges for grinding processes. This technology allows for the creation of high-quality workpieces with a roughness Ra of 5 nm.
In addition to cutting tools, micro grinding tools such as abrasive pencils and burrs can also be produced using the same diamond coating technology. These tools can have very small diameters, as small as 50 mm, and have been successfully tested.
Upgrade your machining capabilities with KINTEK's diamond-coated tools! Our cutting-edge technology ensures optimal performance for machining non-ferrous materials like aluminium-silicon alloys, copper alloys, fibre-reinforced polymers, green ceramics, and graphite. The diamond coating strengthens the tool, reduces friction, and maintains sharpness over time. With customizable surface structures and film thickness, our CVD diamond-coated tools are tailored to enhance your specific applications. Stay ahead of the competition and maximize your productivity with KINTEK. Contact us now!
