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Successful application of PCD direct compression sintering technology
When it comes to machining composite materials, there's no one-size-fits-all solution. Each material and application requires a tailored approach, which is why continuous innovation and practical experimentation are essential. Whether you're working with carbon fiber-reinforced plastics (CFRPs), CFRP-metal laminates (such as aluminum or titanium), or other advanced composites, Sandvik Coromant collaborates with Precorp to deliver cutting-edge tooling solutions that enhance both performance and quality.
One of the most significant advancements in composite drilling tools is PCD direct compression sintering technology. To understand its value, it’s important to first look at the limitations of traditional PCD tools. Typically, flat PCD sheets are brazed onto cemented carbide substrates, but this method has two major drawbacks: limited tool geometry and vulnerability at the brazed joint near the cutting edge. When heat builds up during machining, it can cause the joint to fail, leading to tool wear and reduced efficiency.
To address these challenges, Sandvik Coromant and Precorp have focused on manufacturing PCD tool blanks using direct compression sintering. This process involves placing diamond powder into grooves in the carbide body and sintering them under high temperature and pressure. The result is a more durable and precise tool blank that allows for complex cutting geometries, such as spiral edges, which are not achievable with traditional welded PCD flat sheets.
This innovation offers several advantages. It enables accurate positioning of the PCD blade, supports the creation of intricate cutting edges, and reduces the risk of failure due to heat. Additionally, the brazed joint is located away from the cutting zone, making it less susceptible to thermal stress. These improvements lead to longer tool life, better surface finish, and higher productivity—especially when machining challenging composites like CFRP-metal stacks.
In terms of tool edge design, PCD direct-pressed tools maintain sharpness even when cutting high-wear materials. They can also be optimized with rounded corners to increase cutting speed without compromising surface quality or dimensional accuracy. For high-stress applications, micro-grinding techniques help maintain sharpness and extend tool life, reducing issues like delamination, fiber pull-out, and surface damage.
Drilling remains a critical operation in composite machining, particularly in industries like aerospace. Sandvik Coromant’s PCD drills, such as the 85 and 86 PT series CD10, are designed for optimal performance in various materials. They feature specialized groove geometries that minimize delamination and improve hole quality. When used with automatic feed systems, these drills include protective layers that reduce the exposed PCD length, enhancing stability and longevity.
For fixed-bed CNC machines, the CoroDrill® 859V is optimized for unidirectional tape materials like M21E, offering excellent performance on coated CFRP. When working with CFRP-metal stacks, specific drill designs like the 86A and 86B series are used, with different center angles to suit aluminum or titanium combinations, minimizing burrs and fiber fragmentation.
Even in the toughest cases, such as CFRP-titanium stacks, Sandvik Coromant and Precorp have developed solutions that significantly improve drilling efficiency. In one test, a 15 mm CFRP layer and a 10 mm titanium sheet were drilled with a cutting speed of about 12 m/min and a feed rate of 0.05 mm/rev, achieving excellent results.
While one-shot drilling is ideal for reducing cycle time, precision often requires multiple steps—pre-drilling, drilling, and reaming. However, Sandvik Coromant is pushing the boundaries of what’s possible with single-pass drilling on complex composites. Early trials have shown promising results, proving that high-quality holes can be achieved consistently and efficiently.
Beyond drilling, PCD direct compression sintering technology is also revolutionizing surface and edge machining. For example, CoroMill® Plura end mills equipped with this technology excel in machining aircraft tail sections made of composite materials, reducing fiber breakage and increasing material removal rates.
In summary, PCD direct compression sintering is a game-changer in composite machining, offering unmatched performance, durability, and versatility. As industries continue to demand higher precision and efficiency, this technology stands out as a key driver for innovation and cost reduction across a wide range of applications.