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In recent years, China's super-hard tools have grown significantly and have made great progress. Major manufacturers such as aviation, automotive, and energy industries are also looking for cost-saving needs, and they also hope to make localization of super-hard tools, which provides a development space for the development of super-hard tools in China.
First, the introduction of superhard tools
Superhard tools mainly refer to tools made of superhard materials such as diamond, cubic boron nitride and ceramics. This article focuses on diamond and cubic boron nitride tools.
In 1955, GE Corporation of the United States obtained high-quality and high-pressure methods to obtain synthetic diamond. In 1957, cubic boron nitride (CBN) was synthesized by high temperature and high pressure. These man-made materials have greatly enriched the treasure trove of materials and opened up new areas of “superhard materialsâ€. At the time, the main use of these materials in the field of machining was abrasives. In 1977, GE successfully developed diamond sintered bodies (PCD) and CBN sintered bodies (PCBN) and made them into blades, making the use of artificial superhard materials further. The expansion, from grinding to cutting, has ushered in a new dawn in the development of cutting technology.
Practice has proved that when cutting non-ferrous metals, the durability of diamond tools can be increased by tens or even hundreds of times compared with cemented carbide tools; although cubic boron nitride (CBN) is slightly less rigid than diamond, it is The hardest tool material currently available for processing hardened ferrous metals.
Many cutting concepts, such as green machining, car grinding, milling grinding, hard machining, high speed cutting, dry cutting, etc., are all due to the application of superhard tools. Superhard tools have become the driving force of modern cutting technology. An important factor in the rapid development of high-end. In the high-speed milling of key parts of automobiles, the PCD face milling cutter for machining aluminum cylinder head has a milling speed of 4021m/min and a feed rate of 5670m/min. The CBN face milling cutter for machining gray cast iron cylinders has been milling. Up to 2000m/min, which is 10 times higher than traditional carbide face milling cutters.
Second, the development of modern superhard materials and technology
Foreign companies attach great importance to the continuous research on super-hard materials and tools, and have been conducting continuous research and development. New ideas, new processes and new products are launched almost every year.
Development of superhard material technology
1. The emergence of new PCD brands
In recent years, companies have continuously developed new grades for their use, and their performance indicators have been greatly improved. For example, the PCD grade of a British company, wpc102, adopts a multi-layer structure: a 350 um composite pcd base layer, a 20 um composite pcd intermediate layer, and a 30 um top metal layer. It enhances the anti-cutting impact ability and improves the toughness of the cutting edge. It is suitable for microscopic and macroscopic interrupted cutting and cutting edge chipping failure, such as processing carbon fiber reinforced plastics. In the same way, the company produced CTM302 with mixed particles for the early product CTB025 (diamond fine powder particles 25μ) by mixing 2μ with 25μ. Practice has proved that the wear resistance and toughness of this model are greatly improved. A US company PCD grade: compax1200, structure: 1.5um grain size, enhanced heat dissipation, applied to poor thermal conductors, such as Ti6Al14V.
2. Single crystal diamond technology and progress
It was originally a high-end high-precision tool made of natural single crystal diamond. Since natural diamond is not recyclable, more than 90% of single crystal diamonds on the market today are made of artificial single crystal. Because it is pure diamond, it has high wear resistance and can sharpen a sharp edge. Disadvantages: Single crystal diamond has anisotropy and high processing requirements; the manufacturing tool is affected by the size of the single crystal itself; the cost is high.
Third, challenges and prospects
(1) Achievements in the development of China's superhard tool industry
China's superhard tools have made great progress after a long period of development, as follows:
Established a group of powerful super-hard tool specialization enterprises, equipped with advanced equipment for producing super-hard tools, super-hard materials continue to innovate, high CBN concentration blades can be compared with foreign products, and made for various industries Contribution.
(II) The gap in the development of China's superhard tool industry
1. Weak in the raw material link (high dependence on imported raw materials)
For the CBN tool, the market situation feedback shows that the domestic high-content CBN tool blank is not bad, and in some cases it can be comparable to the imported CBN. However, in the case of lower CBN tools, the effect is not good.
For PCD tools, the market situation feedback and the evaluation of each tool manufacturer is: in most cases, the domestic PCD composite film is still not used.
2. The overall level of domestic superhard tool is low and lacks independent innovation ability: the performance of composite film is poor; the product quality is unstable; the product variety and specifications are small; the self-developed less imitation is more; the lack of complete equipment and R&D power of foreign companies; Hard tool manufacturers mostly have a complete set of supporting facilities from the super-hard raw material preparation process → cutting → machining → welding technology → surface treatment → sharpening process → detection (dynamic balance) → safety → use technology → research and development talents Team and means.
Domestic tool manufacturers often miss some of these links.
3. Advantages of the development of China's superhard tool industry
Although there is still a certain gap between China's super-hard tool industry and foreign countries, in recent years, China's super-hard tool growth momentum is obvious, there are many favorable conditions:
The rapid development of cutting technology and new materials has put forward higher and higher requirements for tool materials, which has further promoted the development of superhard tools. With the popularization of domestic CNC machine tools, users are becoming more and more aware of superhard tools. High; the cost of super-hard tools is gradually decreasing, and the threshold for users to use super-hard tools is decreasing year by year; major manufacturers such as aviation, automotive, and energy industries want to save costs, and also hope to make super-hard tools localized, providing China's super-hard tool development. The development space; China's super-hard tool level is also increasing year by year, and gradually gained the recognition of the majority of users.
It can be seen that due to the performance of the super-hard tool itself and the market demand, the super-hard tool industry will continue to grow at a high speed.
(III) Suggestions on the development of China's superhard tool industry
Material manufacturers pay attention to serialized and targeted research and development
Processing and manufacturing enterprises pay attention to the transition from digestion and absorption innovation mode to independent innovation mode
Closer integration of “production, learning, research and use†With the advancement of science and technology, the rapid development of manufacturing industry, the rapid development of CNC processing technology and the widespread use of CNC machine tools, the production and application of super-hard tools are becoming more and more extensive. . PCD and PCBN tools have been widely used in various industries of machining. With the joint efforts, China's super-hard tool industry will surely lead to a booming spring.
Abstract Introduction: In recent years, China's super-hard tools have grown significantly and have made great progress. Due to the performance of superhard tools and the market demand, the superhard tool industry will continue to grow at a high speed. In recent years, China's super-hard tool growth momentum is obvious, has achieved a lot of...
Introduction: In recent years, China's super-hard tools have grown significantly and have made great progress. Due to the performance of superhard tools and the market demand, the superhard tool industry will continue to grow at a high speed.