Application of Diamond Tools in Cast Iron Processing

At present, the tools used for machining cast iron in China are mainly cemented carbide tools, corundum (or silicon carbide) abrasive tools, etc. These tools have the disadvantages of low processing efficiency, poor processing quality, and low tool safety. Especially in the processing of wear-resistant cast iron and cast iron parts of the white mouth layer, the sand layer, this type of tool shows a clear adaptation. Drawing on the design philosophy of Japan's Reagan Company for diamond saw blades for cast iron slicing, we also developed a series of products such as diamond burrs and diamond drills while producing the same products so that the diamond tool satisfies slotting and cutting of cast iron. Requirements for several different operations such as grinding and drilling. Compared with traditional tools, diamond tools have doubled in terms of processing quality, service life, and processing efficiency. They have shown high efficiency, low consumption, and safety.

[Technical Solution and Principle]

The tool is manufactured by electroplating (electroforming), which is an electroplated metal bond diamond tool.

For the characteristics and application requirements of cast iron materials and diamond tools, the key issues in the design and manufacture of tools are addressed in the following areas:

1. Bonding strength between metal plating and substrate

The cutting and grinding of cast iron parts are often in a non-cooling water environment, ie, dry cutting and dry grinding. For the electroplating products, the temperature of the tool itself is increased without cooling, making it easy to make the plating and the substrate. Cracking causes the coating to fall off. To solve this problem, take the following designs:

1) The base material is made of a low expansion coefficient alloy steel. The metal salt near the base material component is selected as the main salt of the bath to reduce the thermal expansion coefficient difference between different materials between the base and the coating.

2) Pre-plating the Cu layer on the substrate surface as a transition layer to increase the bonding strength between the substrate and the plating layer;

3) The substrate uses an electrical activation process;

4) Different plating solutions are used in the sand plating and thickening plating processes to improve the internal stress state of the coating and reduce the abnormal peeling factor of the coating.

2, the workpiece processing efficiency

Since the diamond tool is a diamond micro-cutting surface with a surface covered with a diamond micro-cutting blade to process the cast iron, the use of a cutting edge that is clogged or blunt by the cutting chips may affect the efficiency. In order to solve this problem, the following design is adopted:

1) Use high quality coarse grain diamond single crystal as cutting edge;

2) Control the depth of diamond particles embedded in the coating by controlling the thickening time to ensure that the average edge height is more than 0.1mm.

3) Optimize electroplating process, use plating solution circulation, filtration, profiling anodes, etc., to improve the distribution of power lines in the electric field, make the plating smooth, reduce the appearance of metal tumors

3, security issues

Adopt high-quality steel plate, design reasonable structure form, eliminate stress concentration, thus avoiding matrix cracking during use

[Experiment and Application]

Based on the above principles, diamond tools designed for different operating situations are designed and manufactured:

1、 Diamond saw blade

This product adopts a preferred design scheme for cutting, cutting and cutting of risers, cast pipes, and piston rings of cast iron parts.

The substrate is made of annealed alloy steel plate, and the cutting edge is made of MBD12 grade 40/45 grain size diamond single crystal. To prevent the saw blade from being scratched during operation, the RVD70/80 diamond single crystal protection plate is applied on both sides of the substrate.

The product is subjected to the following cutting test:

Experimental machine: Fixed cutter RC-16 type Power: 2.2KW Spindle speed: 1900r/min

Cut off the object: QT40-17 diameter 30mm Annealed hardness HB230

Experimental method: Load: 2Kgf No cooling, cut off

The experimental data is as follows:

Saw blade specifications

Cut off quantity

Consumption time:

12 inches

15

14 inch

1

20

The application shows that the life of the product is equivalent to 50-80 times that of the same size resin cutting blade, and the operation is convenient, the safety is high, and the labor intensity is low.

The appearance and specifications are as follows:

2, diamond grinding

This product is used for the cleanup of cast iron parts, removal of flashes, burrs, etc.

The base body is made of cold-rolled steel plate, which is finished after molding. Abrasives use MBD8 grade 40/456 particle size.

The application shows that the life of this product is equivalent to 30-50 times that of resin-type grinding wheel of the same specification, and the safety is extremely high.

The appearance and specifications are as follows:

3, diamond drill

Used for core drilling in cast iron pipe under special conditions.

The base body is made of 45 steel tubing, and the MBD8 grade 40/456 grain size is used as the abrasive.

The application shows that the product features high efficiency and high safety

The appearance and specifications are as follows:

[in conclusion]

Through reasonable design and experiments, it has been proved that the diamond tools with optimized technology can be used to process cast iron materials, and these tools show good performance.