Mirror Processing Single Crystal Diamond Tool
High-precision micro-mirror mold the shape of the post-processing accuracy and surface roughness requirements are very high, the original “rough cutting + grinding + mill” in the processing methods not only to take a long time, but the shape is not suitable for fine grinding In addition, the shape of grinding will produce micro-defects such as edge collapse, so that the shape of an unsatisfactory accuracy.
Made of single crystal diamond tool to a very sharp serrated cutting edge without a bump, can be done simply by cutting high-precision micro-machining tooling mirror. Single crystal diamond tool is mainly used for DVD and digital camera detector mirror plastic mirror lens mold processing.
As the diamond trade and the iron group metal chemical reaction, therefore not suitable for machining hardened steel workpiece material is confined to the processing of non-electrolytic nickel and other non-ferrous metals. In recent years, due to the ultrasonic elliptical vibration cutting machines to improve performance, single crystal diamond cutting tool of hardened steel can be used for iron group metals mirror finish. The following brief and sharp with excellent cutting performance of single crystal diamond tool cutting edge features and application examples.
(1) the characteristics of single crystal diamond cutting tools
Is well known, diamond is the highest hardness, thermal conductivity, the best tool material, processing materials in hard machining, dry and semidry machining has a long service life. Single crystal diamond is a carbon atom (C) through the covalent bond closely to achieve strong and single crystal materials. Through high-precision grinding, single crystal diamond tool can be very sharp teeth of the cutting edge without a bump. PCD is a polycrystalline diamond, which is bonded by metal under high temperature and pressure by the micro-diamond particles sintered polycrystalline diamond body, but the fine grain of the grain boundary, there are combined with metals. Polycrystalline diamond particles as the combination of weaker than single crystal diamond, thus sharpening the cutting edge will be generated after the bump crystal interface and particle shedding phenomenon.
(2) processing of aluminum alloy mirror
With arc-shaped cutting edge processing A5056 aluminum alloy single crystal diamond tools (processing conditions: cutting speed: 300m/min, machining allowance: 0.05mm, feed speed: 0.04mm / r, tip R: 0.5mm, front Angle: 0 °, after the angle: 7 °), machined surface can clearly see tool marks, the level of knife marks to the mirror, that is realized close to the theoretical surface roughness of the mirror finish. Polycrystalline diamond tools used in the processing line can be seen cut into the surface to the cut marks, cut marks to the left into a cutting edge formed by the bump bump processing traces. Carbide turning tools using the same standard machined surface, turning cutting edge all the powder particles is reflected in the processing of the rough surface, leaving the cutting direction of the cut mark, but not into the knife marks observed. Single crystal diamond tools for processing surface (Ry0.238 m, Rz0.166 m, Ra0.034 m) and polycrystalline diamond tools machined surface (Ry1.327 m, Rz1.149 m, Ra0.261 m) comparison can be seen, single crystal the surface of diamond tools for the processing of a high-quality mirror.
(3) hardened steel diamond tool machining ultrasonic elliptical vibration mirror
As the single crystal diamond with strong affinity for iron group metals, so the past can not be used single-crystal diamond cutting tool of hardened steel and other steel to mirror finish. With the diamond and iron can inhibit the reaction of the ultrasonic elliptical vibration cutting technology development success, has been able to achieve with single-crystal diamond cutting tool machining of hardened steel mirror. Recently, through the ultrasonic elliptical vibration cutting device to improve, to achieve a practical level. Ultrasonic elliptical vibration cutting two-dimensional cutting model shows that cutting edge tool for elliptical motion, chips and diamond tools rake face in the same direction, which can inhibit the friction, the same time, there is gap between the two, inhibit the diamond reaction with iron, so iron group metals processing can be cutting aluminum, non-electrolytic nickel plating layer as the mirror.
Single crystal diamond cutting tool is mainly used for non-spherical lens, diffraction grating high-precision processing of optical components. With the ultrasonic elliptical vibration cutting technology continues to improve and extend the application of single crystal diamond tool in machining of hardened steel mold mirror the application will be popular.
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