Diamond Segment Production Process
The production process of diamond segments (used in tools like saw blades, grinding wheels, or core bits) involves several critical steps to ensure high performance and quality. Below is a general outline of the process:
- Material Preparation
Diamond Selection: Choose suitable diamond particles (synthetic or natural) based on the application and the material to be processed. Control particle size and concentration for optimal performance.
Metal Powder Selection: Select bonding agents (e.g., cobalt, copper, iron, nickel powders) and mix them in specific proportions. The bonding agent determines the toughness and wear resistance of the segment. - Mixing
Blend diamond particles and metal powders to ensure uniform distribution.
Use mixing equipment (such as ball mills or mixers) to homogenize the materials. Add small amounts of lubricants if necessary. - Pressing (Shaping)
Mold Preparation: Use a specialized mold to press the mixed material into the desired shape (e.g., rectangular, fan-shaped).
Pressure Control: Adjust pressing pressure based on the size and material characteristics to achieve the required density and initial strength. - Sintering
Hot Press Sintering: Sinter the pressed segments under high temperature and pressure. This enhances the density of the metal bond and firmly fixes the diamond particles.
Cold Press Sintering: For cost-effective segments, cold pressing followed by high-temperature sintering might be used.
Atmosphere Control: Perform sintering in a vacuum, inert gas, or other protective environments to prevent oxidation and maintain material properties. - Welding
Attach the sintered segments to the tool substrate (e.g., saw blade, drill bit, or grinding wheel) using welding methods such as high-frequency welding, laser welding, or brazing.
Ensure the segments are securely bonded to the substrate, meeting the strength requirements for specific applications. - Post-Processing
Dimension Adjustment: Remove burrs and ensure precise dimensions of the segments.
Surface Treatment: Polish or coat the surface to enhance corrosion resistance.
Quality Inspection: Perform visual inspections, hardness tests, impact resistance tests, and cutting performance tests. - Performance Testing
Cutting Tests: Test the cutting efficiency and lifespan of the segments under actual working conditions. - Optimization Feedback: Adjust process parameters based on test results to meet various application requirements.
- Key Considerations
Uniform Diamond Distribution: Ensure even distribution of diamond particles during mixing and shaping to prevent localized wear.
Bonding Agent Quality: Select appropriate bonding agent formulas to balance sharpness and wear resistance.
Sintering Process Control: Precisely control sintering temperature and duration to avoid over-sintering or under-sintering.
By carefully managing each step of the process, high-quality diamond segments with excellent performance and durability can be produced to meet diverse cutting and grinding needs.
