Drilling machinability of engineering ceramics under low-frequency axial vibration processing by sintering/brazing composite diamond trepanning bit

Abstract

Abstract Thin-wall diamond trepanning bits are extensively used for processing hard and brittle materials such as engineering ceramics. However, it is difficult to achieve high-efficiency processing of engineering ceramics at a constant feed speed, because of high dynamic compressive strength, high hardness, and low density of engineering ceramics. In this study, a novel composite diamond bit combining sintering and brazing has been designed, along with the low-frequency axial vibration technology, to realize the continuous hole processing of engineering ceramics. Drilling experiments have been conducted on Al2O3 and SiC engineering ceramics with a constant feed speed. The variation of axial force, micromorphology of hole wall surface drilled, as well as the method of removing nesting during the drilling process were analyzed. According to the results, the novel composite diamond bit fabricated by combining sintering and brazing, can achieve the continuous hole processing of engineering ceramics at a constant feed speed, including Al2O3 and SiC. Compared to the conventional drilling (CD), the low-frequency axial vibration drilling (LFVD) can significantly reduce the axial force, and produce fewer plastic scratches on the hole wall surface drilled. In particular, the automatic blanking ratio approaches to 100% by LFVD, and only about 73.58% by CD. It can be concluded that LFVD technology can be used to realize continuous hole processing of engineering ceramics. The research results achieved in this study show that the drilling machinability of engineering ceramics by LFVD and novel composite diamond bit is good. Accordingly, this study provides a useful reference for continuous processing or batch production of engineering ceramics at a constant feed speed.