The manufacturing process of diamond tools involves several key steps, which may vary depending on the type of tool (e.g., diamond saw blades, diamond drill bits, diamond grinding wheels) and its application. Below is a common manufacturing process:
- Raw Material Preparation
Diamond Particle Selection: Choose appropriate diamond particles (grain size, shape, concentration) based on the tool’s intended use. Both natural and synthetic diamonds are options.
Bonding Material Selection: Select suitable bonding materials, such as metal bonds (e.g., copper, cobalt, nickel) or resin bonds, depending on the tool’s performance requirements. - Mixing
Mix diamond particles and bonding materials in a specific ratio to ensure uniform distribution.
Mixing Methods: Use mechanical stirring or ball milling. - Pressing and Shaping
Mold Design: Design specialized molds based on the tool’s shape.
Cold Pressing: Place the mixture into the mold and cold press it to form a preliminary shape.
Hot Pressing: Perform hot pressing under controlled temperature and pressure (suitable for metal bonds) to ensure a strong bond between diamonds and the bonding material. - Sintering
Sintering is a critical step aimed at solidifying the bonding material and enhancing the tool’s strength.
Sintering Methods: Hot Press Sintering: Common for high-performance diamond tools like saw blades.
Cold Press Followed by Sintering: Used for tools with complex shapes or low-temperature bonds.
Temperature and Pressure Control: Ensure proper control to avoid diamond degradation, such as carbonization or loss. - Post-Processing
Trimming: Perform mechanical processing like cutting, turning, and grinding to achieve precise dimensions.
Surface Treatment: Apply rust-proof coatings or polishing to enhance the tool’s appearance and durability.
Embedding: Attach the sintered diamond segments to the tool’s base (e.g., steel substrate). - Quality Inspection
Appearance Inspection: Check whether the tool’s size and shape
