The Fabrication Of The Ordered PDC Cutter Tool And The Study On The Cutting Properties

This paper is aimed at developing and preparing a new ordered PDC cutter which replaces the abrasives in a grinding wheel or the inserts in a cutting tool with PDC fibers. PDC fibers are first artificially aligned along the desired direction and distributed in a mold and fixed with epoxy resin to make the PDC pieces. The specially ordered PDC pieces are then lapped with diamond abrasive to get sharp cutting edges and the necessary clearance angles; finally,prepared a new structural ordered PDC cutter through assembling the PDC pieces. The ordered PDC cutter has a low ratio of normal to tangential grinding forces,desired geometries (e.g., rake angles)and edge space among PDC fibers, meanwhile it has a large number of cutting edges than the conventional cutting tools. Machining with the ordered PDC cutter is expected to provide both good surface finish and high machining efficiency at the same time.The study compares the machining properties of the ordered PDC cutter with that of the diamond grinding wheel in machining the WC/12Co coating, and it further discusses the cutting mechanism and the wear mechanism of the ordered PDC cutter based on investigation of the cutting force and machinied surface as well as the physical properties of the WC/12Co coating.The experimental results indicate that the quality of the machined work-piece surface is equal to that of machined by diamond grinding wheel, meanwhile, the ordered PDC cutter requires the lower machine stiffness because it has a low normal to tangential force ratio, and it can obtain high material removal efficiency through increasing the number of the PDC fibers with the cutting edges. It is found that the rake face of the ordered PDC cutter appear cavities and slight abrasive wear in the cutting process, and the cutting edges of the ordered PDC cutter exihibits the tipping due to the collision with the workpiece.The ordered PDC cutter combines the advantages of grinding wheel and cutting tools, it is an innovation to cutting tool and has a wide market potential and application prospect.