Abstract : The manufacturing industry is increasingly focused on developing products that are multi-functional and high-performing. In recent years, the push for eco-friendly products has become more urgent due to growing environmental concerns. At the same time, the materials used in these products are constantly evolving, driven by the need for better performance and sustainability. Currently, the industry is accelerating the development of advanced materials and technologies to meet these challenges. In sectors like automotive, aerospace, and semiconductors, traditional iron-based materials are being gradually replaced by high-strength, lightweight composite materials. This shift aims to improve efficiency while maintaining structural integrity and reducing energy consumption.
The use of composite materials, such as Carbon Fiber Reinforced Plastics (CFRP) and Metal Matrix Composites (MMC), presents new challenges in machining. These materials often contain hard constituents that make them difficult to cut, leading to rapid tool wear. To address this issue, diamond-coated tools have emerged as a highly effective solution, particularly in applications where precision and durability are essential.
In the aerospace sector, CFRP has become a key material due to its strength-to-weight ratio. For example, Boeing's 787 Dreamliner uses CFRP extensively, making up nearly half of the aircraft’s structure. As demand for fuel-efficient aircraft grows, the use of such materials is expected to rise further. However, machining CFRP can be problematic, as the carbon fibers may not be fully severed during cutting, resulting in burrs or tool damage. Adjusting tool geometry, such as reducing the helix angle, can help mitigate these issues and improve surface quality.
Another challenge comes from machining MMCs, which combine metal matrices with ceramic reinforcements like silicon carbide or alumina. These composites are widely used in high-performance applications but are difficult to machine due to their hardness. Diamond-coated tools have proven to be more durable in such scenarios. A drilling test using diamond-coated drill bits showed that Mitsubishi’s coated tools lasted significantly longer than those from other manufacturers, highlighting the importance of strong adhesion between the coating and the substrate.
Overall, the adoption of diamond-coated tools is becoming crucial for efficiently processing difficult-to-machine composites. As product demands continue to diversify, the role of advanced machining solutions will only grow. This paper explores real-world examples of how diamond tools can enhance productivity and reduce tool wear in the manufacturing of complex materials like CFRP and MMC.
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Guangdong Kinen Sanitary Ware Industrial Co.,Ltd. , https://www.kinengroup.com