Research on the Process of Cutting PCD With Fiber Laser Cutting Machine

1. Introduction to PCD

PCD Blanks are a new material made by pressing diamond micro powder into a hard alloy matrix and co sintering it at high temperature and high pressure. It has the advantages of high hardness of diamond (HV ≈ 10000) and high impact toughness of hard alloy. At present, it is widely used in the processing fields of petroleum drill bits, geological exploration, metal processing tools, woodworking tools, 3C processing tools, wear-resistant parts tools, etc. However, diamond composite materials face problems such as low efficiency, large thermal damage, and limited accuracy due to their extremely high hardness and complex double-layer structure when processed into finished products. At the same time, the cutting seam is wide (usually>300 μ m), and the material loss rate is high.

2. Fiber laser cutting technology and advantages

In recent years, with the development of laser technology, its application in the field of cutting superhard materials has become increasingly widespread, especially in the field of polycrystalline diamond composite cutting (PDC). Through continuous blade trial production, the machining accuracy, efficiency, and material utilization have been greatly improved.

With the update and development of technology, fiber laser cutting uses high-energy density laser beams (wavelength 1064) for local non-contact processing, causing the processed material to vaporize or melt locally. The technology offers the following advantages:

1.      High processing accuracy and minimal material damage: The cutting width can be controlled within 173.10 μ m, with a single-sided taper of ≤ 5.90 ° and a surface roughness Ra ≈ 0.65 μ m. The thermal impact is minimal, avoiding microcracks and stress concentration areas that occur during traditional processing. For example, when cutting PCD flakes with a thickness of 1.6mm, the width of the cutting seam can be controlled within 70 μ m; In a sealed environment, continuous processing can be carried out to ensure processing quality.

2.      High processing efficiency: The cutting speed is 220mm/min (1.6mm thickness PCD), which is 2-5 times more efficient than traditional lamp pump lasers. It can complete the cutting of complex structural components in a few minutes, reducing the processing time of individual pieces from hours to minutes.

3.      Energy saving and environmental protection: With high photoelectric conversion rate, the power consumption is 10% lower than traditional lasers of the same power. No need for a chiller, lower operating costs.

4.      Good adaptability: It can meet the cutting needs of various shapes of PCD knives, and even process PDC composite sheets for petroleum, mining, CBN, PCBN, CVD, etc. Widely applicable, suitable for rapid development of non-standard parts.

3、 Process characteristics and cutting effect of fiber laser cutting PCD

Process Characteristics

1、    Non contact machining: During laser cutting, there is no contact between the cutting torch and the workpiece, and there is no tool wear. To machine parts of different shapes, simply change the output parameters of the laser.

2、    Clean processing environment: The entire processing process has low noise, minimal vibration, and no pollution. The deformation and thermal deformation of the processed parts are also very small.

3、    Fast processing speed and high efficiency: It is a relatively efficient processing method, especially suitable for processing complex shaped parts.

cutting effect

1.      Cutting quality: The cutting seam is narrow, the material loss is minimal, and the resource utilization rate is high. And the cutting surface is smooth, clean and free of impurities, providing convenience for subsequent processing.

2.      Processing accuracy: The CNC system can accurately control the cutting path, making the dimensional error very small, thereby ensuring the geometric accuracy and shape consistency of the product.

3.      Surface quality: Non contact processing avoids stress deformation caused by hydraulic fixtures. There is no mechanical vibration, no micro cracks on the surface, protecting the integrity of the grain boundaries of the alloy steel and effectively improving the fatigue life of the product。

4、 TKD CO., LTD PCD Fiber Laser Cutting Machine Professional Advantages

As a pioneer in laser processing of superhard material in China, TKD CO., Ltd took the lead in applying laser technology to the cutting process of PCD promoting the upgrading of the entire industry. From the initial use of YAG laser to the most advanced fiber laser in China, the company has always been at the forefront of laser technology development. The founder of TKD previously served as the director of the equipment research and development department at SF DIAMOND CO., LTD. With years of professional technical accumulation and rich frontline experience, TKD has laid a solid foundation for technological innovation, enabling TKD to control cutting more finely, optimize costs, and drive new trends in the field of superhard materials in the entire domestic industry.

TKD CO., LTD PCD Fiber Laser Cutting Machine specializes in cutting PCD and has the following core competitiveness:

1.      Significant improvement in processing efficiency: Complex structures can be completed in just a few minutes, reducing the processing time for a single piece from a few hours to a few minutes compared to traditional methods.

2.      Controllable processing quality: Under the precise control of the CNC system, the cutting size error is extremely small, which increases the finished product qualification rate by more than 20% and can perfectly meet the accuracy requirements of customers.

3.      Stronger adaptability: Supports PCD blade cutting of various shapes, and can also process PCD, PDC, CBN, PCBN, CVD, etc. It has a wide range of applications, strong compatibility, and can better meet the rapid development of non-standard parts for customers.

4.      Advanced Integrated Cooling Systems: By combining air cooling, it effectively suppresses the overheating of graphite compounds between diamond grains, thereby ensuring processing quality.

5.      More advanced path planning technology: compatible with advanced path planning technology。

5、 Summary

Fiber laser cutting technology has brought efficient and high-quality solutions for precision machining of PCD. By accurately controlling the motion trajectory of the laser beam through a numerical control system, the requirements for one-time forming and processing of complex structures can be achieved.

The advantages include: improved product accuracy, significantly increased processing efficiency, and excellent surface quality. TKD CO., LTD PCD fiber laser cutting machine provides customers with an efficient and high-quality solution in the field of superhard materials with professional performance and a wide range of processing fields.

Looking to the future: Technology is becoming increasingly mature, and equipment will continue to be optimized. Fiber laser cutting will play an increasingly important role in the manufacturing of PCD. With the continuous advancement of high-end manufacturing in aerospace, automotive, mold and other fields, the market's requirements for cutting technology will also become increasingly high. TKD CO., LTD will continue to invest in research and development, strive to create greater achievements in the global market, and promote the sustainable development of the entire manufacturing industry.