Name: PCD Diamond Blanks for Wire Drawing Dies manufacturer
Brand: MORE
Availability: InStock

Product Details

PCD Diamond Blanks for Wire Drawing Dies manufacturer

PCD(Polycrystalline Diamond)is a synthesized, extremely tough, intergroup mass of randomly orientated diamond particles in a metal matrix. It is produced by sintering together selected diamond particles at high pressure and temperature.

According to different particle size of polycrystalline diamond layer, ZK series diamond compact have six granularity types to choose from, such as2μm、5μm、10μm、25μm、35μm、302. 2μm and 5μm ones used for super finishing machining, 10μm ones used for fine finishing, and 25μm、35μm and302 ones used for rough finishing.

Product Number	MORE 10
Diamond Dimensions(μm)	8~12
Diamond Content (Vol%)	≥95
Product Feature	① Good electrical discharge machining ② Long Life ③ Better heat resistance and impact resistance
Applications	Fine machining, very good surface processing quality, for aluminum alloy(Si content ＜12%), copper alloy, composite wood processing, high-precision wear resistant corbelled device, etc...

Product	Diamond Grain Size (μm)	Diameter	Height(T) (mm) (± 0.05)	Diamond Layer Thickness (t) (mm)
ZK02	2	Φ45	1.6、2.0、3.0	0.5 ± 0.15
ZK05	5	Φ45	1.6、2.0、3.0	0.5 ± 0.15
ZK10	10	Φ45	1.6、2.0、3.0	0.5 ± 0.15
ZK25	25	Φ45	1.6、2.0、3.0	0.5 ± 0.15
ZK35	35	Φ45	1.6、2.0、3.0	0.5 ± 0.15
ZK302	2+30	Φ45	1.6、2.0、3.0	0.5 ± 0.15
ZK02H	2	Φ45	1.6、2.0、3.0	0.5 ± 0.15
ZK05H	5	Φ45	1.6、2.0、3.0	0.5 ± 0.15
ZK10H	10	Φ45	1.6、2.0、3.0	0.5 ± 0.15
ZK25H	25	Φ45	1.6、2.0、3.0	0.5 ± 0.15
ZK302H	2+30	Φ45	1.6、2.0、3.0	0.5 ± 0.15

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Polycrystalline diamond tools have become an indispensable tool in modern machining. This is mainly reflected in the following aspects:

(1) High-speed cutting, high-stability processing

(2) Ultra-precision mirror processing

(3) Dry cutting and cleaning processing

Performance introduction

The characteristics of Polycrystalline diamond tools(1) High hardness and wear resistance

Polycrystalline diamond has a hardness of up to 10000 HV. It is the hardest material in the world. It is much harder than hard alloys and engineering ceramics. Because of its extremely high hardness and isotropic properties, polycrystalline diamond has extreme Good wear resistance.

(2) Low friction coefficient

The coefficient of friction between polycrystalline diamond and some non-ferrous metals is lower than that of other materials, which is about 1/2 of that of cemented carbide. The low coefficient of friction not only reduces the deformation and cutting force, but also causes no built-up edge during cutting, thus reducing the surface roughness of the machined surface.

(3) High thermal conductivity

Polycrystalline diamond has a high thermal conductivity, which is better than silver and copper. It is much higher than that of ordinary hard alloys. Therefore, the cutting heat is easily dissipated during the cutting process, so the cutting temperature is low.

(4) High processing accuracy

Because the polycrystalline diamond tool has a low coefficient of thermal expansion and a high modulus of elasticity, the tool is not easily deformed during the cutting process. Under the action of the cutting force, the tool can maintain its original parameters, maintain sharpness for a long time, and has high cutting precision. Therefore, when machining with a PCD tool, the cutting force can be reduced and the cutting temperature can be lowered, the tool durability and the cutting rate can be improved, and a good machined surface can be obtained.

The main problem: the high hardness and high wear resistance of PCD materials make molding and surface finishing very difficult, which seriously hinders its popularization and application.

Common processing methods: EDM, laser processing, chemical processing, ultrasonic processing.

Ideal processing method: grinding or grinding.

PCD Full-Round Blanks
	D/mm	Size (AxD)	T/mm	t/mm	Grain size
	58	360 R x55	1.6/2.0/3.2	0.5-0.8	2μ
	50	360 R x50			5μ
	45	360 R x45			10μ
Tolerances:	40	360 R x40			20μ
D = +/- 0.1mm	32	360 R x32			25μ
T = +/- 0.05mm	18	360 R x18			2+25μ
Surface condition: Polished with Mirror-like diamond surface	13	360 R x13
	8	360 R x8
	6	360 R x6

Different shape of PCD blanks / tips
			We can make any shapes and sizes as per client's needs. Tolerance, surface condition,Grain sizes are offered as same as above.



PCD Cutting Tool Blanks Application Recommendation:
Grades	Characters		Applications		Advantages
W2-W5 fine grain	1.Average grain size:2-5μm		Aluminum, Brass/Copper, Precious metals, Wood composites, Plastic		Excellent surface finish
	2.High diamond content over90%
	3.Laser cutting/ wire EDM cutting
W10 medium grain	1.Average grain size:10μm		<14% Si/Al alloys, Copper alloys, Graphite and graphite composites, Green ceramics and carbides		Excellent resistance, good surface finish
	2.High diamond content over90%
	3.Laser cutting/ wire EDM cutting
W20-W25 coarse grain	1.Average grain size:20-25μm		>14% Si/Al alloys, metal matrix composites, Bi-metals(aluminum/cast iron),sintered ceramics and carbides		Long life, extremely high wear resistance
	2.High diamond contentover90%
	3.Laser cutting/ wire EDM cutting

Features compared with tungsten carbide tools:

1, The hardness of PCD is 80 to 120 times that of tungsten carbide.
2. The thermal conductivity of PCD is 1.5 to 9 times that of tungsten carbide.Its thermal conductivity is 700W/mk. The PCD blank can conduct heat fast
3, PCD toolings life can exceed carbide cutting tool life 50 to 100 times.

Features compared with natural diamond tools:
1, PCD is more resistant over natural diamond because of its random orientation structure of the diamond particles, and is backed by a carbide substrate.
2, PCD is more constant in wear due to complete production system for quality consistant control, Natural diamond is a single crystal in nature and has soft and hard grains both,when making into toolings, it will not be well using with soft grains.
3, PCD is cheaper and with various shapes and sizes to choose from for toolings, natural diamond is the limit on these point.