霸刀分享-金刚石涂层刀具适用材料
金刚石涂层刀具适用材料分类及典型应用
金刚石涂层刀具凭借高硬度、低摩擦系数及化学稳定性，在特定材料加工中表现优异。其适用材料主要分为非铁基金属材料、非金属材料和复合材料三大类，具体细分及加工特性如下：
一、非铁基金属材料
此类材料不含铁元素，避免了金刚石与铁族元素的化学反应，适合高效加工：
· 铝及铝合金：包括高硅铝合金（如汽车发动机缸体、活塞），金刚石刀具可实现镜面级光洁度，加工效率是硬质合金刀具的3-5倍。
· 铜及铜合金：适用于电机整流子、转子等精密部件，刀具寿命可达硬质合金的10-20倍。
· 其他非铁金属：如锌合金、铅合金、巴氏合金等，尤其适合高速切削和高精度成型加工。
二、非金属材料
金刚石涂层刀具对非金属硬脆材料的加工优势显著，具体包括：
· 高分子材料：有机玻璃、尼龙制品、环氧树脂等，切削力小且无黏结现象。
· 陶瓷与矿物材料：氧化铝、碳化硅、玻璃陶瓷、石墨等，可实现低表面粗糙度（Ra≤0.1μm）。
· 脆性非金属：电木、烧结陶瓷、石墨模具等，刀具耐磨性远超传统硬质合金。
三、复合材料
针对纤维增强或填充型复合材料，金刚石涂层刀具可有效避免刀具磨损和分层缺陷：
· 纤维增强塑料：碳纤维增强塑料（CFRP）、玻璃钢、环氧玻璃纤维等，刀具寿命可达未涂层硬质合金的70倍
填充型复合材料：碳填充材料、尼龙填充材料、硅酸类填充材料等，加工效率提升显著。
四、材料加工的限制与禁忌
需特别注意，铁族金属（如钢、铸铁、镍合金）不适合使用金刚石涂层刀具。原因在于高温切削时，铁会与金刚石中的碳原子发生化学反应，导致涂层化学磨损失效。此外，加工含钛、钨等强碳化物形成元素的材料时，也需谨慎评估刀具寿命
通过合理匹配材料类型与刀具特性，金刚石涂层刀具可显著降低加工成本、提升生产效率，尤其在难加工材料领域具有不可替代的优势。
Ba Dao Sharing - Applicable Materials for Diamond-coated Tools
Classification of applicable materials and typical applications of diamond-coated cutting tools
Diamond-coated cutting tools perform exceptionally well in the processing of specific materials due to their high hardness, low friction coefficient and chemical stability. The applicable materials are mainly divided into three categories: non-ferrous metal materials, non-metallic materials and composite materials. The specific classification and processing characteristics are as follows:
1. Non-ferrous metal materials
This type of material does not contain iron elements, avoiding the chemical reaction between diamond and iron group elements, and is suitable for efficient processing
• Aluminum and aluminum alloys: including high-silicon aluminum alloys (such as automotive engine blocks and pistons), diamond tools can achieve a mirror-like finish, and their processing efficiency is 3 to 5 times that of hard alloy tools.
• Copper and copper alloys: Suitable for precision components such as commutators and rotors of motors, the tool life can reach 10 to 20 times that of hard alloys.
Other non-ferrous metals: such as zinc alloys, lead alloys, Babbitt alloys, etc., are particularly suitable for high-speed cutting and high-precision forming processing.
Ii. Non-metallic materials
Diamond-coated cutting tools have significant advantages in processing non-metallic hard and brittle materials, specifically including:
• Polymer materials: organic glass, nylon products, epoxy resin, etc., with small cutting force and no adhesion phenomenon.
• Ceramic and mineral materials: alumina, silicon carbide, glass ceramics, graphite, etc., can achieve low surface roughness (Ra≤0.1μm).
• Brittle non-metals: bakelite, sintered ceramics, graphite molds, etc. The wear resistance of cutting tools far exceeds that of traditional cemented carbides.
Iii. Composite Materials
For fiber-reinforced or filled composite materials, diamond-coated tools can effectively prevent tool wear and delamination defects:
Fiber-reinforced plastics: carbon fiber reinforced plastics (CFRP), fiberglass reinforced plastics, epoxy glass fibers, etc. The tool life can reach 70 times that of uncoated cemented carbide
• Filled composite materials: carbon-filled materials, nylon-filled materials, silica-filled materials, etc., have significantly improved processing efficiency.
Iv. Limitations and Taboos in Material Processing
It should be particularly noted that iron group metals (such as steel, cast iron, and nickel alloys) are not suitable for using diamond-coated cutting tools. The reason is that during high-temperature cutting, iron undergoes a chemical reaction with the carbon atoms in diamond, leading to chemical wear and failure of the coating. In addition, when processing materials containing strong carbide-forming elements such as titanium and tungsten, it is also necessary to carefully assess the tool life
By rationally matching material types with tool characteristics, diamond-coated tools can significantly reduce processing costs and enhance production efficiency, especially in the field of difficult-to-machine materials, where they have irreplaceable advantages.