Abstract
This paper presents a nanosecond-fiber-laser-based method for manufacturing polycrystalline-diamond (PCD) tool blanks. The effects of variations in the process path and operating parameters on the cut-surface morphology and surface-quality of the processed PCD workpieces have been analyzed. The results obtained in this study reveal the reactive fusion cutting mechanism to yield a processing depth of 155.2 µm at 30-W average laser power, 200-ns pulse width, and 30-kHz pulse frequency. The successful cutting of a 1.2-mm-thick PCD workpiece via implementation of the horizontal-shifting and vertical layer–by-layer processing methods is reported. Compared to the wire-electrical-discharge machining (WEDM), the proposed approach yields superior cut-surface roughness (Ra = 0.378 µm). Moreover, the laser processing was performed on a single-axis curved stage, on which the workpiece placed at an inclination during laser cutting and finishing. Thus, a PCD insert with an orthogonally cut edge, flat and pit-free finishing surface, and excellent tool-surface roughness (Ra = 0.202 µm) was obtained, thereby verifying the feasibility of the proposed approach. Furthermore, it is evident that the nanosecond-fiber laser can be used to not only cut and finish PCD inserts but also produce PCD workpieces oriented at different rake and clearance angles.
Highlights
Polycrystalline diamond (PCD) manufactured by high-pressure synthesis is a highperformance synthetic super-hard material with high compressive strength, high wear resistance, good thermal conductivity, low thermal expansion coefficient, and favorable chemical stability [1]
In the manufacturing of PCD tools, wire electrical discharge machining (WEDM) is commonly used to cut the PCD material into a tool blank, which is welded to the tool-holder and polished and finished using a diamond grinding wheel [8]
The PCD workpiece was fixed with an overhang and clean dry air was supplied at pressure of six bar
Summary
Polycrystalline diamond (PCD) manufactured by high-pressure synthesis is a highperformance synthetic super-hard material with high compressive strength, high wear resistance, good thermal conductivity, low thermal expansion coefficient, and favorable chemical stability [1]. PCD has greater fracture toughness than single-crystal diamond and ceramic materials; it can be used in cutting tools to obtain excellent machining accuracy and efficiency [2,3]. In the manufacturing of PCD tools, wire electrical discharge machining (WEDM) is commonly used to cut the PCD material into a tool blank, which is welded to the tool-holder and polished and finished using a diamond grinding wheel [8]. The discharge pulse will cause surface pits on the cut surface, which will reduce the strength of the material. It needs to be polished with a diamond wheel during post-treatment
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