Quality Test
Hardness testing: Vickers hardness tester is often used to test the hardness of the tool blanks by pressing the diamond indenter into the surface of the tool blank under a certain load and measuring the diagonal length of the indentation to calculate the hardness value, in order to ensure that the hardness meets the requirements for use.
Structure Inspection: The crystal structure is analyzed by X-ray diffractometer to determine the crystalline state and grain size of the diamond to ensure that the blanks have a uniform crystal structure and are free from defects and impurities.
Thickness Inspection: Use laser thickness gauge or contact thickness gauge to accurately measure the thickness of the tool blanks to ensure that the thickness uniformity is within the specified range, so as to ensure the stability of the tool's performance in the process of use.
Application Advantages
High machining accuracy: capable of high-precision cutting, low machining surface roughness, which can reach Ra0.01 - 0.1μm, suitable for processing of optical components, precision molds and other fields with extremely high requirements for precision.
High machining efficiency: Due to its high hardness and wear resistance, the cutting speed is several times higher than that of traditional tools, and the feed can be increased accordingly, which greatly improves the machining efficiency and reduces the machining cost. For example, when processing graphite electrodes, the cutting speed of CVD polycrystalline diamond tools can reach 1000 - 2000m/min, which is 5 - 10 times that of carbide tools.
Development challenges
Bonding with the substrate: Despite the continuous development of CVD technology, the bonding between the diamond film and the substrate still needs to be further improved. During high-speed cutting and heavy-load machining, tool blanks may spall or delaminate, affecting tool life and machining quality. At present, researchers improve the bonding force by pre-treating the surface of the substrate, optimizing the deposition process and adding a transition layer, but further in-depth research is still needed.
Large-area uniformity: With the increasing demand for large-size CVD polycrystalline diamond tool blanks in industrial production, how to ensure the thickness uniformity and performance consistency of large-area blanks is a key issue. In the deposition process, due to the reaction gas distribution, plasma density and other factors, it is easy to lead to differences in the performance of different parts of the blank. Solving this problem requires the optimization of deposition equipment and processes, and the development of more advanced gas transport systems and plasma control technology.
Development prospects
Application expansion in emerging fields: with the rapid development of new energy vehicles, 5G communication, artificial intelligence and other emerging industries, the demand for high-precision, high-performance tools will continue to increase. cvd polycrystalline diamond tool blanks have a broad application prospect in these fields, such as in the battery manufacturing of new energy vehicles, can be used for processing high-precision electrode materials; in the field of 5G communication, can be used for processing high-performance radio frequency devices and optical components. devices and optical components.
Green manufacturing trend: CVD polycrystalline diamond tool blanks are in line with the trend of green manufacturing. Its high hardness and wear resistance can reduce the frequency of tool replacement, reduce the consumption of tool materials and the generation of waste; at the same time, green machining processes such as dry cutting or micro-lubrication cutting can be used in the machining process to reduce the use of cutting fluid and reduce the pollution of the environment. Therefore, under the background of increasingly strict environmental protection requirements, CVD polycrystalline diamond tool blanks will be more widely used and promoted
