Discussion on Machining Solutions for Positioning Holes with Ultra Hard PCD Cutting Tools and Intelligent Laser Manufacturing

PCD (Polycrystalline Diamond) cutting toolsare popular in high-end precision machinery manufacturing, such as new energyvehicle three electric systems and aerospace composite material processing, dueto their extremely high hardness and wear resistance. However, the"double-layer composite structure" of PCD diamond layer and hardalloy substrate also poses great technical challenges for positioning holemachining. High end manufacturing factories in Germany and Europe have verystrict requirements for the aperture tolerance (≤±0.01), roundness (± 0.005), and micro heat affectedzone (HAZ) of positioning holes.

1、 Comparison of mainstream machining methods for PCDpositioning holes

In response to the characteristics of PCDmaterials such as superhard wear resistance, high brittleness, and multiphasestructure, the industry currently mainly adopts the following three processroutes for processing. The quantitative performance comparison of each schemeis as follows:

Comparison Table of Key TechnicalParameters for PCD Positioning Hole Machining:

2.Apply strategy

A. Fine positioning hole

1)       Main process flow: Industrialnanosecond laser(1064 ) processing combined with coaxial image positioningprocessing.

2)       Key points of the process: Usea gas protective cover to prevent slag from adhering to the hole wall, reducingand assisting external factors. Adopting micro scanning method for layer bylayer scanning, and then optimizing the process through a round of laserdrilling to achieve process integration chamfering. This can not only preventcorner radius, but also increase the corner radius of micro parts clamped bythe blade edge.

B. Deep hole batch processing (H/D>8:1)

1)       Production solution: Laserdrilling combined with EDM sinking machining.

2)       Key process points: Use laserfor rough machining. After drilling in the center, about 0.05mm of processingspace is reserved. The final dimensions are machined using a high-speed coppertungsten wire EDM center. This scheme comprehensively considers the advantagesof efficient laser and micro electrical discharge machining of fine pores,achieving HAZ=0.

3.TKD CO., LTD Intelligent Precision FiberLaser Engraving Machine Product Promotion

TKD CO., LTD has launched a new generationof industrial grade precision fiber laser engraving machine to meet the demandfor 3D precision machining of rotatable blades and non-standard shaped parts.This device integrates high flexibility, high efficiency, and intelligence,making it an ideal choice for the transformation and upgrading of superhardtool manufacturing plants.

Core technical parameters of TKD precision laser engraving machine

Why choose TKD laser solution?

1)       Breaking through conductivitylimitations: Traditional electrical machining cannot cope with non-conductiveceramics and low cobalt PCD. TKD laser equipment uses non-contact high-energybeam ablation to easily overcome the bottleneck of all material processing.

2)       In line with Germany/Europe'sgreen environmental protection indicators: no mechanical wear throughout theprocess, no need to consume cutting fluid or spark oil, no wastewater or wasteresidue pollution, helping enterprises pass strict green factory and carbonfootprint certifications.

3)       Extremely high return oninvestment (ROI): Compressing the traditional processing steps that often taketens of minutes to seconds, significantly reducing the cost of single pieceprocessing, and helping your products enter the international high-end supplychain.

For a visual demonstration of the practicalapplication of this machining process, you can refer to the PCD FIBER LASER EngravingMachine. This video visually demonstrates the actual engraving and processingperformance of TKD fiber laser equipment on superhard PCD/CBN tool materials.

==========FAQ==========

FAQ 1: Machining Accuracy and Tolerance

Q: Can TKD’s laser machining solution meet the strict tolerance requirements for European tool factories?

A: Yes, absolutely. High-end manufacturing plants in Germany and Europe typically demand an aperture tolerance of ≤± 0.01 and roundness within 0.005mm for PCD/CBN positioning holes. TKD’s precision fiber laser solutions achieve a dimensional accuracy of 0.005  and a surface roughness ofR_a 0.3-0.8. By pairing ultra-precision X/Y linear slide stages with high-definition coaxial vision tracking and real-time auto-focus, our equipment consistently delivers micron-level alignment and eliminates human error during high-mix production.

FAQ 2: Laser vs. Traditional EDM

Q: What are the core advantages of using TKD laser engraving over traditional EDM for PCD/CBN groove and hole machining?

A: Compared to traditional Wire EDM or die-sinking EDM, the TKD precision laser solution offers three disruptive advantages:No Material Conductivity Limits: Traditional EDM fails when processing low-cobalt PCD or non-conductive advanced ceramics. TKD’s high-energy "cold ablation" beam cuts through any superhard material seamlessly.

Zero Consumables & Tool Wear: Unlike EDM which suffers from severe electrode wear and high spark oil costs, laser is a non-contact process with zero tool wear, ensuring maximum ROI.

FAQ 3: Thermal Damage and Heat Affected Zone (HAZ)

Q: Does laser drilling cause micro-cracks or a severe Heat Affected Zone (HAZ) on PCD tools?

A: No. TKD utilizes advanced industrial 1064nm nanosecond laser processing combined with high-frequency layered micro-scanning to achieve a clean "cold ablation" mechanism, which effectively eliminates structural thermal stress.

Furthermore, for deep hole batch processing, we offer a smart Laser and EDM hybrid strategy. We utilize high-speed laser for rapid rough machining while reserving a precise $0.05text{ mm}$ processing margin, followed by a final pass using a high-speed copper tungsten wire EDM. This hybrid process completely wipes out thermal degradation, achieving perfect surface integrity with HAZ = 0

FAQ 4: 3D Geometries and Chip Breakers

Q: Can the TKD precision laser engraving machine handle complex 3D structures like chip breakers and curved tool geometries?

A: Yes. The TKD machine is specifically engineered for the 3D precision profiling of rotatable blades and non-standard shaped tools. It is equipped with an advanced 3D Digital Galvo Scanner that supports automatic 3D slice rendering and multi-layer deep engraving. This allows tool manufacturers to complete monolithic, single-setup profiling of complex 3D chip breakers, curved geometries, fine positioning slots, and integrated chamfering without multiple re-clamping steps.

FAQ 5: Green Manufacturing and Carbon Footprint

Q: How does TKD’s laser solution help European tool makers comply with strict green factory and environmental certifications?

A: Environmental and carbon footprint standards in Germany and across Europe are exceptionally rigorous. Traditional machining relies heavily on cutting fluids, grinding wheel waste, or spark oil, which create wastewater and hazardous waste residues. TKD's laser solution is completely dry and eco-friendly. There is zero mechanical wear, zero oil/fluid consumption, and zero hazardous fluid emissions. Integrating our machines helps your enterprise pass strict green factory audits, lower carbon footprints, and smoothly enter the high-end international supply chain.