SELECTION OF MATERIALS FOR CUTTING TOOLS

CUBIC BORON NITRIDE &

POLY CRYSTALLINE DIAMOND

PREPARED BY
N.KARTHICK
2009606001
¼ M.E.MANUFACTURING ENGG
ANNA UNIVERSITY – MIT
 INTRODUCTION
CUBIC BORON NITRIDE
 Second hardest material

 In 1957, by R.H.Wentorf Jr. of the General Electric

Company, USA
 Artificially manufactured

 Cost-effective rapid stock removal

 Finishing of hardened steels & Certain softer

ferrous materials
 Replaces Al2O3 wheels
 PROPERTIES
 Generally yellow, orange
 Crystal system – Cubic

 Hardness ~ 4500 HK

KHN = F/A = P/CL2

(C = 0.07028 = Constant of indenter )

 Specific heat [J/(mol K)]

12.55 at 300 K
25.1 at 600 K
 Melting point at triple point

~ 3500 K
 APPLICATIONS
Typically they are used for hard ferrous materials (RC
45 or harder) that are difficult to machine with carbide
or ceramic or that require time consuming grinding
operations.

 • Automotive engine blocks - Cylinder Boring

• Brake rotors - O.D. Facing and Chamfer
• Transmission gears - I.D. Boring
• Steel mill rolls - O.D. Turning
• Cylinder head - Milling
 ADVANTAGES
ROUGHING :
• Efficient machining of pearlitic gray cast iron
• Turning hard facing alloys
• Machining of powder metal alloys
• Turning of superalloys
FINISHING :
• High speed finish machining of hardened steel
(>45 RC)
• Suitable for continuous machining of hardened
steels
• Replace grinding operations.
 SOME APPLICATIONS

Machining Case Hardened Steel

Turning with CBN
Gear
Rough and semi-finish turning, Machining White Iron Roll with
milling, Grooving and boring CBN
 SPLINTER SIZE
OF THREE REPRESENTATIVE CBN GRADES
AT HEATED AND UNHEATED CONDITIONS
 POLY-CRYSTALLINE DIAMONDS
 Diamond is the hardest, most abrasive-
resistant which makes diamond an ideal
cutting tool
 Polycrystalline Diamond blanks produced
under conditions of high pressure (1 million
PSI) and temperature (1700 Degrees C),
similar to those of diamond synthesis
THREE MAIN REASONS FOR USING PCD
TOOLS:-

 Increased tool life results in reduced tool cost

per component and less idle machine time.
 Increasing cutting speed improves productivity
through reduced cycle times.
 Grinding and other less productive machining
methods can be replaced by PCD milling and
turning.
POLY – CRYSTALLINE DIAMONDS EXIST
BOTH IN NATURE AND ARTIFICIAL.
NATURAL PCD
 Carbonado, commonly known as the "Black
Diamond", is a natural polycrystalline diamond
found in alluvial deposits in the Central African
Republic and Brazil. Its natural colour is black or
dark grey, and it is more porous than other
diamonds
ARTIFICIAL PCD
 In 1976, the Baker Hughes Inc. company
introduced bits with synthetic diamond cutters
called polycrystalline diamond compact (PDC) bits.
 PROPERTIES OF PCD
 Vickers Micro hardness 25.0 - 98.0 Gpa
 Modulus of Elasticity 749 – 953 Gpa

 Poisson’s Ratio 0.0700 - 0.200

 Density 3.00 - 4.00 g/cc

 Colour - Clear

 Crystal Structure - Cubic

 APPLICATIONS
 Can be inserted into PCD cutting tools, PCD drilling
bits/core bits, PCD wire drawing dies, reamers and
other wear resistant components.
 Well suited to high speed cutting of aluminium,
particularly when good surface finishes are
mandatory.
 Recommended for cutting high content silicon
aluminium alloys.
 Used on brass, copper, carbide and bronze in
applications including turning, boring, profiling,
grooving, milling and hole making.
 Used for oil field drilling and coal mining.
MANUFACTURING DIFFERENT SHAPES
OF PCD
 ADVANTAGES
 The results obtained in drilling medium to hard rocks and
non – uniform abrasive formations are much better than
those obtained with drill bits impregnated or surface-set
with single natural diamond crystals.

 A factor that improves the toughness of poly-crystalline

diamond is the presence of cobalt in the microstructure
along with the random orientation of the diamond particles.

 The tungsten carbide substrate also provides mechanical

support for the diamond abrasive layer, increasing impact
resistance and making it easier for braze attachment in tool
fabrication.
 Another benefit of poly-crystalline diamond bits is the
range of diamond grades available to fit any nonferrous
application.

 Typically, fine-grain diamond is used for less abrasive

applications requiring an excellent surface finish.
Medium-grain diamond is considered a general-
purpose machining grade. Coarse-grain diamond is
used in rough machining and in extremely abrasive
materials where surface finish may not be as important.

 It also excels in machining highly abrasive work pieces.

 DISADVANTAGES

Because of a chemical interaction

between diamond and iron, poly-crystalline
diamond bits are not typically used to cut
ferrous materials. However, diamond bits can
be used to tackle bimetal applications
involving aluminium and cast iron.
PHYSICAL PROPERTIES OF SOME PCD PRODUCTS
COMPARISONS OF SOME CBN PRODUCTS
 REFERENCES
 http://
www.springerlink.com/content/x584423376016731/fulltext.
pdf

 http
://www.cutting-tool.americanmachinist.com/guiEdits/Conte
nt/bdeee15/bdeee15_1.aspx
.

THANK YOU