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Manufacturing Process
Cold Pressing
Fine alumina powder compressed into required form
Sintered in furnace at 2912 F to 3092F
Hot Pressing
Combines forming and sintering with pressure and
heat being applied simultaneously
Ceramic Inserts
Stronger inserts developed
Aluminum oxide and zirconium oxide mixed in
powder form, cold-pressed into shape and sintered
Indexable Insert
Most common
Fastened in mechanical holder
Available in many styles: square, round,
triangular, rectangular
When cutting edge
becomes dull, sharp
edge can be obtained by
indexing (turning) insert
in the holder
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
Ceramics Usage
1. High-speed, single-point turning, boring, and
facing operations with continuous cutting
2. Finishing operations on ferrous and
nonferrous materials
3. Light, interrupted finishing cuts on steel or
cast iron
Ceramics Usage
4. Machining castings when other tools break
down because of abrasive action of sand,
inclusions or hard scale
5. Cutting hard steels up to hardness of
Rockwell c 66
6. Any operation in which size and finish of part
must be controlled and previous tools not
satisfactory
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Cutting Speeds
Use highest cutting speed possible that gives
reasonable tool life
Two to ten times higher than other cutting
tools
Less heat generated due to lower coefficient
of friction between chip, work, and tool surface
Most of heat generated escapes with chip
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Manufacture of Polycrystalline
Cutting Tools
Two distinct types
Polycrystalline cubic boron nitride
Polycrystalline diamond
Polycrystalline Mass
Created from substrate composed of tiny grains
of tungsten carbide cemented tightly together
Cobalt binder
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High Pressure
High Temp
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Qualities built into turning and milling buttingtool blanks and inserts
Can operate at higher cutting speeds, and take
deeper cuts
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Hardness
Abrasion Resistance
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Compressive Strength
Thermal Conductivity
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Full-faced inserts
Layer of PCBN bonded to cemented-carbide
Available as triangles, squares and rounds
Can downsize repeatedly
Brazed-shank tools
Made by machining pocket in proper-style of
tool shank and brazing PCBN blank in place
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Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Hardened steels
Cast irons
3. Heat-resistant alloys
4. Superalloys (jet engine parts)
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Advantages of
PCBN Cutting Tools
High Material-Removal Rates
Cutting speeds (250 to 900 ft/min) and feed rates
(.010 to .020 in.) result in removal rates three time
carbide tools with less tool wear
More Advantages
High Quality Products
Wear very slowly
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High Pressure
High Temp
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Diamond layer
Hardness, abrasion resistance, compressive
strength, and thermal conductivity
Compressive strength highest of any tool
Thermal conductivity highest of any tool
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2.
3.
4.
5.
Tungsten carbide
Advanced composites
Ceramics
Wood composites
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Diamond-Coated Tools
Early 1980s brought new process of chemical
vapor deposition (CVD)
Produce diamond coating few microns thick
Process
Elemental hydrogen dissolved in hydrocarbon gas
around 1330
Mixture contacts cooler metal, carbon precipitates in
pure crystalline form and coats metal with diamond
film (slow 1-5 microns/hr)
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QQC
Process developed by Pravin Mistry in mid
1990s
Eliminated problems of adhesion, adjusting to
various substrates, coating thickness and cost
Process creates diamond film through use of
laser energy and carbon dioxide as source of
carbon
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QQC Process
Laser energy directed at substrate to mobilize, vaporize
and reate with primary element (carbone) to change
crystalline structure of substrate
Conversion zone created
beneath substrate surface
Changes metallurgically
to composition of
diamond coating on
surface
Diffusion bonding of
diamond coating to substrate
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More Advantages
Only carbon dioxide primary or secondary source
for carbon; nitrogen acts as shield
Diamond deposition rates exceed 1 micron per
second
Process can be used for wide variety of materials
Tool life up to 60 times better than tungsten
carbide and 240 times better than high-speed
steel
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