I. Introduction
PCBN (polycrystalline cubic boron nitride) composite sheet, as a superhard material, plays a vital role in the field of modern industrial processing. With the continuous improvement of the manufacturing industry's demand for high-precision and high-efficiency processing, the research on PCBN composite sheets has become increasingly in-depth. This report aims to systematically sort out its related characteristics, preparation process and application.
II. Characteristics of PCBN composite sheets
(I) Hardness characteristics
PCBN composite sheets have extremely high hardness, which is second only to diamond. This enables it to effectively cut into the material for cutting when processing hard metal materials such as various alloy steels and cast iron, and maintain a good edge shape, reduce tool wear and extend the service life of the tool.
(II) Thermal stability
It has excellent thermal stability and can still maintain good physical and chemical properties under high temperature environment. During the cutting process, a large amount of heat will be generated due to friction, and PCBN composite sheets can withstand high temperatures and will not easily soften or deform, thereby ensuring processing accuracy and quality.
(III) Chemical inertness
PCBN composite sheets are chemically inert to most metal elements and are not easy to react chemically with the processed materials during processing, thus avoiding problems such as reduced processing surface quality due to chemical reactions, and are conducive to obtaining high-quality processing surfaces.
III. Preparation process of PCBN composite sheets
(I) Raw material selection
To prepare PCBN composite sheets, high-quality cubic boron nitride powder must first be selected as the basic raw material, and a suitable binder must be used at the same time. Commonly used binders include metal binders, ceramic binders, etc. Different binders will give the composite sheets different performance characteristics, which need to be selected according to specific application requirements.
(II) High-temperature and high-pressure synthesis
Using a high-temperature and high-pressure synthesis process, the raw materials are placed in a specific high-temperature and high-pressure environment. After a period of reaction, the cubic boron nitride powder and the binder are fully combined to form a dense composite structure. In this process, the control of parameters such as temperature, pressure and reaction time has a key impact on the final performance of the composite sheet.
(III) Post-processing process
The synthesized PCBN composite sheet also needs to go through post-processing processes such as cutting, grinding, and polishing to achieve the required dimensional accuracy and surface finish to meet the use requirements in different processing scenarios.
IV. Application fields of PCBN composite sheets
(I) Metal cutting processing
In the automotive manufacturing industry, it is used for the processing of engine cylinders, crankshafts and other parts; in the aerospace field, it can be used for precision processing of various high-temperature alloys, titanium alloys and other difficult-to-process materials to improve processing efficiency and part quality.
(II) Stone processing
For natural stone and artificial stone with high hardness, PCBN composite sheet tools can quickly perform cutting, grinding and other operations, and ensure the flatness and glossiness of the processed surface, improving the overall level of stone processing.
(III) Other fields
In some emerging high-end manufacturing industries, such as the cutting of hard and brittle materials such as silicon wafers in electronic chip manufacturing, PCBN composite sheets have also begun to be gradually applied, showing its broad application potential.
V. Development Trends and Challenges
(I) Development Trends
In the future, PCBN composite sheets are expected to develop towards higher performance. By optimizing the preparation process and developing new binders, their comprehensive properties such as hardness, toughness and wear resistance can be further improved. At the same time, its application areas will continue to expand and extend to more high-precision and high-difficulty processing scenarios.
(II) Challenges
However, the current preparation cost of PCBN composite sheets is still relatively high, which limits its wider application and popularization. In addition, the performance stability under complex working conditions needs to be further improved, and scientific researchers need to continue to overcome related technical difficulties.
VI. Conclusion
PCBN composite sheets play an important role in many industrial fields with their excellent performance. Although they are currently facing some challenges, with the continuous deepening of research and the continuous advancement of technology, their development prospects are very broad and are expected to provide strong support for promoting the high-quality development of the manufacturing industry.
