With the increasing application of superhard materials like PCD (Polycrystalline Diamond) and CBN (Cubic Boron Nitride) in industries such as automotive, motorcycle manufacturing, air conditioning compressors, and wood processing, the demand for these tools has significantly risen. In China, around 20 companies are now involved in the development, production, and sharpening of superhard tools. However, most of them focus on low-end products—such as blade-mounted tools with minimal precision requirements—leading to intense market competition. To cut costs and improve efficiency, many enterprises are seeking localized processing and sharpening solutions for these high-performance tools.
High-precision welding-type PCD tools require strict technical specifications. The tool holder typically uses an HSK adapter or a straight shank mounted in an HSK hydraulic chuck. The PCD tool length is under 150mm, with a diameter less than 50mm. The blade diameter tolerance must be within 0.003mm, and the accuracy grade should reach IT2–IT3. The coaxiality tolerance for IT3-grade tools must also be controlled at 0.003mm. Achieving this level of precision is challenging due to the combination of grinding errors and tool mounting inaccuracies. Ensuring the outer diameter tolerance of 0.003mm requires not only high-Precision Machining equipment but also meticulous control over the grinding process. Additionally, measuring such tools demands instruments capable of micron-level accuracy, with a measuring force kept below 150mN to avoid distortion.
The FC-500D PCD & CBN tool grinder from Yuanshan Machinery Co., Ltd. is designed to meet these demanding standards. It features a 500mm grinding wheel travel, sufficient for tools up to 150mm in length. With a rotary table and corner display function, it can achieve reverse taper grinding for cutting edges with ratios ranging from 1:1000 to 1:1500. The machine uses Swiss Schneeberger high-precision linear guides for both the wheel base and table rail, ensuring stability and accuracy. The feed system employs pneumatic flexible adjustment, allowing for precise 1μm increments. The contact pressure between the grinding wheel and the tool is adjustable, and the grinding head height can be adjusted for larger-diameter tools. A high-precision CCD camera system provides real-time visualization of the sharpening process, with magnifications from 15x to 120x, and can detect arc radii as small as 0.05mm.
To enable precise sharpening, the machine includes an indexing work head with fine-tuning capabilities. This head uses a SK40 spindle inner hole and worm gear mechanism for accurate positioning. The 24-divided indexing plate allows for even divisions of 2, 3, 4, 6, and 8 parts. For other divisions, such as 5 or 7, alternative plates are used. A reducer sleeve is also employed when working with HSK handles, ensuring proper alignment and minimizing coaxiality errors. The reducer sleeve is adjustable, allowing for fine-tuned centering and maintaining the required 0.003mm tolerance during reinstallation.
An online measuring device is integrated into the machine, enabling real-time measurement of tool dimensions and circular runout. The device is mounted on the table and moves with it, keeping the same position as the tool. It features vertical and horizontal carriages that allow for precise adjustments in both axial and radial directions. The measuring head assembly includes fixed and moving components, with a grating scale providing 1μm accuracy. The measuring force is kept below 150mN to ensure reliable readings.
The sharpening process involves several key steps, including aligning the tool’s axis with the spindle, adjusting the cutting edge position, and grinding the back angles. After sharpening, the tool is measured using the online device to confirm its diameter and roundness. If necessary, further adjustments are made until the desired specifications are met.
Edge treatment is crucial for extending tool life. By optimizing the cutting edge and reducing initial wear, the tool can maintain dimensional stability longer. Dynamic balancing is also essential, especially for high-speed applications. Tools must be balanced according to ISO 1940/4 standards to prevent vibration and ensure smooth operation.
Finally, the machining environment plays a critical role in achieving consistent results. Proper temperature control, dust-free conditions, and careful handling of tools and fixtures are all necessary to maintain the high precision required for PCD tool sharpening. Operator skill and training are equally important, as manual operations demand a high level of expertise to produce reliable, high-quality tools.
1. High Accuracy and Precision
Precision machining processes are capable of achieving extremely tight tolerances, often down to thousandths of an inch or even less. This high level of accuracy is crucial for the production of components that must fit together perfectly and function reliably in applications where there is little margin for error.
2. Complex Geometries and Detailed Parts
With advanced CNC machinery and sophisticated programming, precision machining can produce complex shapes and intricate details that are not possible with less precise manufacturing methods. This capability is essential for creating components with specific functional geometries, such as those found in aerospace, medical devices, and electronics.
3. Superior Surface Finishes
Precision machining can achieve excellent surface finishes, reducing or eliminating the need for additional surface treatment processes. A high-quality surface finish is not only aesthetically pleasing but can also improve the performance of a part, such as reducing friction or enhancing wear resistance.
4. Material Versatility
Precision machining processes can work with a wide array of materials, including both ferrous and non ferrous metals, plastics, ceramics, and composites. This versatility allows us to choose the optimal material for a given application based on properties like strength, weight, corrosion resistance, and cost.
5. Efficiency and Speed
CNC and automated precision machining processes are highly efficient, capable of producing parts quickly and with minimal waste. This efficiency is beneficial for both short production runs, where it can reduce lead times, and large-scale production, where it can significantly decrease overall manufacturing costs.
6. Consistency and Reproducibility
Automated precision machining ensures that each part is produced to the same specifications as the last, providing excellent consistency and repeatability. This reliability is crucial for manufacturers who need to maintain strict quality control standards across large volumes of parts.
7. Reduced Assembly Times
Parts produced with high precision require less time and effort during assembly, as components fit together seamlessly. This not only speeds up the assembly process but also reduces the potential for errors and defects in the final product.
8. Customisation and Flexibility
Precision machining is highly adaptable, making it suitable for custom or specialised projects. We can easily adjust designs and production processes to accommodate unique specifications or changes in demand.
9. Cost Savings in the Long Run
While the initial investment in precision machining technology and equipment can be high, the long-term savings in material costs, reduced waste, and efficiency gains often outweigh these upfront costs. Additionally, the durability and longevity of precisely machined parts can lead to lower maintenance and replacement costs over time.
Precision Machining
PRECISION MACHINING BENEFITS
Precision machining offers a host of advantages that make it indispensable in modern manufacturing processes, particularly for applications requiring high levels of accuracy and consistency. Here are the key benefits:1. High Accuracy and Precision
Precision machining processes are capable of achieving extremely tight tolerances, often down to thousandths of an inch or even less. This high level of accuracy is crucial for the production of components that must fit together perfectly and function reliably in applications where there is little margin for error.
2. Complex Geometries and Detailed Parts
With advanced CNC machinery and sophisticated programming, precision machining can produce complex shapes and intricate details that are not possible with less precise manufacturing methods. This capability is essential for creating components with specific functional geometries, such as those found in aerospace, medical devices, and electronics.
3. Superior Surface Finishes
Precision machining can achieve excellent surface finishes, reducing or eliminating the need for additional surface treatment processes. A high-quality surface finish is not only aesthetically pleasing but can also improve the performance of a part, such as reducing friction or enhancing wear resistance.
4. Material Versatility
Precision machining processes can work with a wide array of materials, including both ferrous and non ferrous metals, plastics, ceramics, and composites. This versatility allows us to choose the optimal material for a given application based on properties like strength, weight, corrosion resistance, and cost.
5. Efficiency and Speed
CNC and automated precision machining processes are highly efficient, capable of producing parts quickly and with minimal waste. This efficiency is beneficial for both short production runs, where it can reduce lead times, and large-scale production, where it can significantly decrease overall manufacturing costs.
6. Consistency and Reproducibility
Automated precision machining ensures that each part is produced to the same specifications as the last, providing excellent consistency and repeatability. This reliability is crucial for manufacturers who need to maintain strict quality control standards across large volumes of parts.
7. Reduced Assembly Times
Parts produced with high precision require less time and effort during assembly, as components fit together seamlessly. This not only speeds up the assembly process but also reduces the potential for errors and defects in the final product.
8. Customisation and Flexibility
Precision machining is highly adaptable, making it suitable for custom or specialised projects. We can easily adjust designs and production processes to accommodate unique specifications or changes in demand.
9. Cost Savings in the Long Run
While the initial investment in precision machining technology and equipment can be high, the long-term savings in material costs, reduced waste, and efficiency gains often outweigh these upfront costs. Additionally, the durability and longevity of precisely machined parts can lead to lower maintenance and replacement costs over time.
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Taiyuan Simis Investment Casting Co., Ltd , https://www.precision-casting.biz