With such parameters, the longer the contact time with the workpiece, the higher the heat generated, the direct effect of which is the shortening of the tool life.
For processing high silicon aluminum alloys, the wear resistance of PCD is fully utilized. Some studies on these materials have highlighted the relationship between tool wear and silicon particle size, and the larger the silicon particles, the higher the wear resistance of the workpiece. See Figure 4.
Figure 4
The quality of the tool will play an important role in the success of aluminum alloy processing applications: low runout will prevent inconsistent load on the cutting edge.
Figure 5
Metal matrix composite
Metal matrix composites (MMC) are made of aluminum or titanium aluminum, which is by far the most common matrix material. Addition to the matrix material is a ceramic reinforcing agent, most commonly in the form of granules, but occasionally more fibrous forms are more difficult to process. A range of ceramic materials are used for MMC, but the most common one is Si. According to the required wear resistance of the material, the added content is 15-40%.
In the following parts, these materials are gradually replacing heavy materials like cast iron:
Brake disc
Engine block
piston
Cylinder liner
When processing MMC, the cutting speed should be compatible with the ceramic content of the material. The higher the content of the ceramic reinforcing agent, the more wear resistant the workpiece is, so the cutting speed should be lower in order to protect the cutting edge. Positive angle cutting edges are generally accepted during aluminum alloy processing, but negative angle inserts provide a reinforced cutting edge for heavily reinforced materials.
Bimetal material
Processing two different materials that appear on one part is often a big challenge. One of the most common applications is face milling of silicon-aluminum materials with grey cast iron cylinder block engine blocks. Machining these bimetallic parts poses a challenge to the tool supplier, and the tool material that is handy when machining one of the metals is usually not very effective for the other metal. For face-to-face milling of silicon-aluminum engine blocks, the solution can be PCD, assuming the following recommendations have been implemented.
When using PCD, you must consider the following conditions: PCD is the perfect cutting tool for machining aluminum alloys. It can be processed at very high cutting speeds while maintaining excellent tool life. Processing iron-based metal gray cast iron with PCD will result in rapid chemical wear. Chemical wear requires heat to develop it, so in order to minimize chemical wear on the PCD tool, the cutting speed should be reduced and sufficient coolant should be used.
For such processing, the best material grade should be the coarse grain size and the PCD30M with the highest possible thermal stability. Efficient machining of bimetallic materials such as silicon-aluminum engine blocks is possible by combining sufficient coolant with the correct material grade at low cutting speeds.
In other existing bimetallic engines, the cylinder block is composed of an aluminum alloy (low Si content), and the cylinder liner is made of powder sintered material, or the cylinder liner is made of MMC material. Carbon fiber composite material
With the goal of improving the power-to-weight ratio, a wide variety of synthetic materials have been developed by mixing fibers (carbon, glass, SiC, aromatic polyamide, etc.) in a matrix such as plastic, aluminum alloy, or titanium alloy. The fibers can be long or short and can be oriented or parallel. Each of these parameters will affect material properties and cutting characteristics.
The most common composite material for aerospace is CFRP (carbon fiber W strong plastic), which is particularly effective for PCD tools. Machining should balance the risk of fiber flaking due to excessive feed rates and the risk of micro-collapse of the cutting edge due to excessive cutting speed.
Even if the sharp cutting edge is going through the soft core, the reinforcement of the carbon fiber will quickly passivate the cutting edge. It is more pronounced on fiberglass reinforced materials. A typical CFRP part is the wing of an aircraft. You can also find bearings, pump parts and sleeves made from this part material.
  Titanium alloy
In the category of superalloys, titanium alloys generally exhibit superior mechanical and chemical properties at elevated temperatures, but are detrimental to processability. With PCD tools, you can use three times the cutting speed of carbide tools and calculate tool life in hours.
Plastic and reinforced plastic
The general feeling is that the processing of plastic materials is easy. However, soft plastics are not always very stable. If the correct cutting parameters are not applied, the machining process always generates heat, which may affect the size and material properties such as surface structure and color. PCD cutters are particularly effective for wear-resistant plastics (reinforced with carbon fiber (CF) and glass fiber (GF) for plastics).
graphite
Most of the processing of synthetic graphite is to produce electrodes. Although graphite is soft, it is very wear resistant. Even when the cutting speed reaches 1000m/min, the tool life of the PCD will still be invincible.
Copper and brass
When there is no alloying, this is a fairly easy to process material. When copper is strengthened with helium, it is necessary to reduce the cutting speed.
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