The PCD composite sheet and the diamond thick film were respectively cut into triangular pieces by laser, and the YG3X cemented carbide insert was ground into a sipe of the same size as the triangular diaphragm by special tooling for use in brazing. There is a high interfacial energy between the diamond thick film and the general metal and its alloy, which is difficult to be infiltrated by the general low melting point alloy, and the weldability of the diamond thick film is poor. In order to improve the weldability between the diamond thick film and the cemented carbide substrate, a special high-strength silver-copper alloy solder is used, and the diamond thick film blade and the PCD blade are welded by a low-temperature brazing process of a hard alloy. The brazed blades are respectively subjected to the same level of surface precision sharpening, the semi-finished sharp grinding uses high-strength, coarse-grained diamond grinding wheels, the fine sharpening uses fine-grained diamond grinding wheels, and the tool-edge circular arcs are used in tooling. Automatic sharpening. After the end mill is assembled and commissioned, its axial and radial circular runout is controlled within 0.002mm.
4 <br> <br>
cutting test machine tool: BI-266 CNC milling machine; measuring instrument: M4P surface roughness measuring instrument; Workpiece material: Aluminum alloy of LY12; Cutting manner: dry cutting. The LY12 aluminum alloy was milled with a diamond thick film end mill and a PCD end mill under the same cutting amount, and the surface roughness of the test piece was measured. The test results are shown in Table 1. After the milling process, the six teeth of the diamond thick film end mill and the PCD end mill were inspected with a 100x microscope. It was found that each tooth passed more than 6,000 cutting impact loads (6 teeth total 36000) After the secondary impact), there is no chipping phenomenon in the teeth. The test results show that the diamond thick film cutter with reasonable cutter head geometry not only has the advantages of PCD end mill, but also can realize super-finishing of large plane.
Table 1 Comparison test results of diamond thick film end mill and PCD end mill | Tool | Workpiece | Cutting amount | Work surface roughness
R a (μm) |
|---|
| Cutting speed (m/min) | Cutting depth (mm) | Running amount (mm/r) |
|---|
| Diamond thick film end mill | LY12 aluminum alloy | 157 | 0.02 | 0.02 | 0.10 |
| PCD end mill | LY12 aluminum alloy | 157 | 0.02 | 0.02 | 0.40 |
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