In modern technology and the increased demand for high-performance materials in various industries, such as Aerospace, Communications, and Semiconductors,
have led to the use of new materials like CFRP, MMC, CMC, Green Ceramics, Sintered Ceramics, and others.
These materials offer various advantages over traditional materials like metal alloys, such as high strength-to-weight ratio, good electrical and thermal conductivity, and improved durability. However, machining these materials is a challenging task, as they are brittle and prone to cracking, leading to increased tool wear and reduced machining efficiency.
CFRP is used extensively in Aerospace industry to achieve high strength to weight ratio.
CMC (Ceramic Matrix Composite) is used in modern jet engine to produce the heat zone blades improving jet engine efficiency.
Brake disks in modern and sport vehicles are made from MMC (Metal Matrix Composites), in this case, Aluminum matrix with SiC hard particles.
Cell phones enclosures and other communication equip. enclosures are made from Aluminum with high (>8%) Silicon content to achieve strength and durability.
In the semiconductors industry, ceramics like c-Si is used for showerhead parts, SiC is used for cooling elements and Quartz is use as furnace tubes.
In nuclear applications, the use of AlB2 and B4C, is common as a neutron absorber and fuel rods cladding.
PCD (Polycrystalline Diamond) cutting tools have emerged as a solution to these challenges and offer several benefits in the machining of these advanced materials.
PCD cutting tools are made of a diamond layer that is sintered to a carbide substrate, creating a cutting edge that is extremely hard, durable, and abrasive resistant. This makes PCD cutting tools ideal for machining materials like CFRP, MMC, CMC, Ceramics, and nonferrous alloys.
One of the main benefits of using PCD cutting tools in these materials is their ability to achieve high precision and accuracy. The hard and durable cutting edge of PCD tools ensures that the cuts are smooth, reducing the need for secondary operations, and leading to improved dimensional accuracy. This is particularly important in the Aerospace industry, where high precision components are required for complex assemblies and aerospace systems.
PCD Drill commonly used in Aerospace in CFRP and GFRP applications.
Another advantage of using PCD cutting tools is the reduced tool wear. The cutting edge of PCD tools is made of diamond, which is the hardest materials known to man. This means that the cutting edge is highly resistant to abrasion and wear, resulting in longer tool life compared to conventional cutting tools. This translates to reduced downtime for tool replacement, increased machining efficiency, and cost savings.
Drill life comparison in CFRP application between PCD and Tungsten carbide drills. Life difference is almost x20
In the Communications and Semiconductors industries, high surface finish is critical for ensuring optimal performance and reliability of the components. PCD cutting tools can achieve high surface finishes due to their fine grain structure, leading to improved surface quality, and reduced roughness. This is particularly important for semiconductors, where the surface finish affects the performance and reliability of the devices. In addition, semiconductors materials, such as single crystal silicon, Alumina, SiC and Quartz, are extremely hard materials, where only PCD tools can be used with reasonable longevity.
PCD micro-Drill 0.75mm used in Semiconductors, in Single Crystal Silicon showerhead plates drilling.
PCD Multi-flute endmill 2.0mm for machining Hard SiC and TC
PCD 3 FL Spiral endmill 1/4″ for machining green Ceramics and Al-Si enclosures for communication Ind.
In conclusion – PCD cutting tools offer numerous benefits in the machining of advanced materials like CFRP, MMC, CMC, green ceramics, sintered ceramics, etc. They provide high precision, accuracy, and surface finish, while also reducing tool wear and increasing machining efficiency. These benefits make PCD cutting tools a valuable tool in the Aerospace, Communications, and Semiconductors industries, and they are likely to play an increasingly important role in these industries as the demand for advanced materials continues to grow.
