Abstract : The manufacturing industry is currently focusing on developing products that are multi-functional, high-performance, and environmentally friendly. As environmental concerns grow, the need for sustainable materials has become more urgent. At the same time, the materials used in product design are constantly evolving to meet new demands. This trend is especially evident in industries such as aerospace, automotive, and semiconductors, where traditional iron-based materials are being gradually replaced by advanced composites. These modern materials offer better strength-to-weight ratios, which help reduce energy consumption without compromising performance. However, this shift also brings new challenges in machining, particularly when dealing with difficult-to-cut composites like Carbon Fiber Reinforced Plastics (CFRP) and Metal Matrix Composites (MMC). In response, diamond-coated tools have emerged as a promising solution due to their exceptional wear resistance and ability to maintain precision during cutting operations. This article explores real-world examples of how diamond-coated tools are being used to machine these challenging materials effectively.
The manufacturing industry is increasingly focused on creating products that are not only high-performing but also eco-friendly. As environmental regulations tighten and consumer awareness rises, the demand for sustainable materials continues to grow. Alongside this, the types of materials used in production are changing rapidly. For instance, in sectors like aerospace, automotive, and semiconductor manufacturing—key areas within the broader manufacturing industry—there has been a noticeable shift from traditional iron-based materials to high-strength, lightweight non-ferrous composites. This change aims to improve efficiency and reduce energy use while maintaining structural integrity.
In terms of composite processing, the techniques and tools required today are quite different from those used in the past. One of the most common composite materials is Carbon Fiber Reinforced Plastics (CFRP), which combines carbon fibers with a resin matrix to create a strong yet light material. Another is Metal Matrix Composites (MMC), which incorporate ceramic particles into a metal base. Both materials contain hard components that make them difficult to machine, leading to significant tool wear. To address this challenge, diamond-coated tools have become an essential part of the machining process, as diamond is the hardest material known and offers excellent resistance to abrasive wear.
When it comes to CFRP, its application in the aerospace industry has grown significantly. With over 14,300 commercial jets in operation today and projections of reaching 31,700 by 2024, there's a strong push to reduce aircraft weight for fuel efficiency. Boeing, for example, uses CFRP extensively in its 787 model, where it accounts for nearly 50% of the fuselage weight. Processing CFRP, however, presents several challenges. The layered structure of the material can lead to issues like fiber pull-out and tool wear, especially when using conventional cutting tools.
One practical example involves cutting a 5 mm thick CFRP plate using a φ10 mm cemented carbide end mill under standard cutting conditions. While burrs often appear on the surface, adjusting the helix angle of the tool—from 30° to 10°—significantly reduces this issue. This is because a smaller helix angle minimizes the upward force that pulls the fibers, resulting in cleaner cuts.
Another test involved four different end mills cutting the same CFRP plate. The uncoated and TiAIN-coated tools showed substantial wear, with coatings peeling off and the base material becoming exposed. In contrast, the diamond-coated tool remained in excellent condition, demonstrating its superior durability and effectiveness in machining CFRP.
Similarly, in the case of MMCs, which are widely used in automotive and semiconductor applications, the presence of hard ceramic particles makes machining extremely challenging. A drilling test using a φ2.6 mm diamond-coated drill bit showed that while some manufacturers' tools failed after just a few holes, Mitsubishi’s diamond-coated drill lasted through 256 holes before failure. This highlights the importance of strong adhesion between the coating and the substrate, which is crucial for long tool life.
In conclusion, as the manufacturing industry moves toward more complex and sustainable materials, the role of diamond-coated tools in machining difficult composites like CFRP and MMC becomes increasingly vital. These tools not only improve machining efficiency but also ensure higher quality and longer tool life. By adopting such advanced solutions, manufacturers can better meet the growing demand for high-performance, environmentally responsible products.
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Guangdong Kinen Sanitary Ware Industrial Co.,Ltd. , https://www.kinengroup.com