Practice of EDM Cutting for PCD
In the modern manufacturing industry, EDM(electrical discharge machining) technology is favored for its high precisionand high efficiency in material processing. In particular, polycrystallinediamond (PCD), as a superhard material, has become increasingly important inthe manufacture of cutting tools in multiple industries due to its uniquephysical and chemical properties. This article will delve into the practice ofEDM PCD, analyze the characteristics and applications of PCD, and introducerelated machine tool brands.
1. Characteristics and applications of PCD
Polycrystalline diamond is a man-madesuperhard material made by mixing and sintering diamond micropowder with ametal catalyst (such as cobalt) under high temperature and pressure. Comparedwith natural diamond, PCD has higher hardness and wear resistance, and becauseof its excellent weldability, it has been widely used in tool manufacturing.Here are some key features of PCD:
1. Extremely high hardness: PCD has ahardness close to that of diamond, enabling it to effectively cut a variety ofhard materials.
2. Excellent wear resistance: Due to thecharacteristics of its structure, PCD tools show a low wear rate during use,which improves the service life of the tool and processing efficiency.
3. Good thermal conductivity: The thermalconductivity of PCD materials is relatively high, which helps to dissipate heatand reduce the risk of deformation and damage of the tool due to excessivetemperature during cutting.
4. Chemical stability: PCD still maintainsits performance in high temperature and corrosive environments and is suitablefor applications under a variety of processing conditions.
PCD is widely used in fields such ascutting, geological drilling, and stone processing. In high-tech industriessuch as aviation, automobiles, and electronics, PCD tools are an ideal materialchoice and provide solutions for the processing of new materials (such asaluminum-based alloys and carbon fiber composites).
2. Processing principle of PCD wire cutting
Wire cutting is a processing method thatremoves materials through pulse discharge between the electrode wire and theworkpiece. The core of PCD wire cutting is to accurately control the operatingconditions to improve cutting quality and efficiency. The following is theprocessing process of PCD EDM wire cutting:
1. Principle of EDM discharge: During thecutting process, a small discharge gap is formed between the electrode wire andthe PCD workpiece. When the voltage rises to a certain value, the current willdischarge instantly in this gap, causing the material to melt and be removed.
2. Multiple pulse discharge: By adjustingthe pulse frequency and discharge time of the power supply, the intensity ofthe discharge and the cutting speed can be controlled, thereby optimizing thecutting effect.
3. Cutting characteristics: The cutting ofPCD is usually affected by its internal structure, so understanding the cuttingmechanism is crucial to improving the processing quality.
Research shows that the PCD EDM wirecutting mechanism can be divided into three levels: polycrystalline diamondlayer, cobalt-rich interface layer and cemented carbide layer. During thecutting process, the cobalt-rich interface layer has the smallest resistance,so the single pulse energy acting on it is the largest, which is conducive tothe effective removal of materials.
3. Research status of PCD EDM wire cutting
Although EDM wire cutting PCD is relativelymature in cutting processing, research on its cutting mechanism is stillincomplete. In recent years, researchers have focused on the following aspects:
1. Improvement of pulse power supply:Improve the stability and controllability of pulse power supply to achieve moreefficient cutting.
2. Process parameter optimization: Explorethe effects of different voltage, frequency, discharge time and otherparameters on cutting quality, speed and tool life to find the bestcombination.
3. Material performance analysis: Usemicroscopic analysis and detection methods to observe the morphology andthermal damage of the workpiece after processing to understand the cuttingmechanism of different materials.
Through in-depth experiments and analysis,researchers hope to provide a scientific basis for the selection of processparameters and quality control of PCD EDM wire cutting, and further improveprocessing efficiency.
IV. Machine tool brand for EDM wire cuttingPCD
Choosing the right machine tool brand isthe key to ensuring cutting efficiency and quality. The following are somewell-known machine tool brands that can provide high-performance EDM wirecutting PCD:
1. AgieCharmilles (Switzerland): Aworld-renowned EDM machine tool manufacturer known for its excellent technologyand high precision.
2. Makino (Japan): Provideshigh-performance EDM machine tools, and its equipment performs well in high-endmanufacturing industries such as aviation and automobiles.
3. Fanuc (Japan): With advanced EDMtechnology and rich product lines, it is committed to providing customers withefficient cutting solutions.
4. Mitsubishi Electric (Japan): Awell-known electrical equipment manufacturer, its EDM machine tool products arepopular in the market.
5. Sodick (Japan): Specializes in theproduction of EDM machine tools, focuses on technological innovation, and iscommitted to providing efficient cutting tools.
6. EDM Machines (USA): Providescomprehensive EDM solutions and is known for its high-precision technology.
7. ONA (Spain): Its EDM machine tools arewidely used in the field of metal processing and provide high-quality cuttingservices.
8. GF Machining Solutions (Switzerland): Ahigh-end EDM machine tool supplier, focusing on high-precision industries suchas aviation and automobiles.
9. Jingcheng Machinery (CHMER, Taiwan): Awell-known EDM machine tool manufacturer with a rich product line covering theneeds of multiple industries.
10. Taiwan YIH KUAN: specializes in theproduction of electrode processing machines and EDM machine tools, combiningtechnical control with processing efficiency.
11. Chun Chen (Taiwan): widely used in thefield of high-precision cutting with its stable quality and reliability.
12. Taiwan Shin Fuu: provides a variety ofEDM processing solutions to meet different process requirements.
V. Summary and Outlook
PCD wire cutting provides efficient andprecise processing solutions for the manufacturing industry. The continuousadvancement of its technology and the gradual optimization of processparameters have enabled PCD to be widely used in many fields. With theemergence of new materials and the improvement of processing accuracyrequirements, future research will focus more on the combination of wirecutting technology and emerging materials to promote the application scope andmarket demand of PCD tools.
When choosing wire cutting machine tools,users should consider the product characteristics and technical support ofdifferent brands based on their own processing needs, process requirements andbudget. Through cooperation with machine tool manufacturers, optimizing processflow and regular technical training, enterprises will bring higher productionefficiency and better market competitiveness.
With the advancement of science andtechnology, laser cutting technology has gradually replaced the traditional EDMcutting method, especially in cutting superhard materials such as PCD(polycrystalline diamond). EDM cutting is inefficient and slow, and cannot meetthe needs of modern industry for high efficiency and high precision. Lasercutting has the advantages of fast cutting speed, energy saving, environmentalprotection, and pollution-free, especially fiber laser cutting, which has noconsumables and has been widely recognized by the market.
Since TKD CO., LTD launched the firstgeneration of YAG laser cutting machine in 2010, the company has always focusedon providing advanced laser cutting solutions for the field of superhardmaterials. In 2014, TKD applied fiber laser technology to the cutting ofsuperhard materials such as PCD for the first time, marking anotherbreakthrough in the company's laser cutting technology. After more than tenyears of development, TKD laser cutting equipment has been widely used inwoodworking tools, metal tools and superhard materials companies, withcustomers in the United States, Germany, Italy, Turkey, Spain, Russia, Chinaand India.
TKD CO., LTD is committed to providingcustomers with efficient and high-quality laser cutting solutions. If you haveany questions about cutting, please contact us and we will wholeheartedlyprovide you with professional solutions.
