聚晶金剛石復(fù)合片及其生產(chǎn)工藝簡述

聚晶金剛石復(fù)合片及其生產(chǎn)工藝簡述(1)聚晶金剛石復(fù)合片全部選用國產(chǎn)原材料，經(jīng)過重新整形、提純、凈化、配料、組裝等工序，在國產(chǎn)六面頂(液)壓機(jī)上，采用先進(jìn)的超高壓-高溫合成工藝，生產(chǎn)聚晶金剛石復(fù)合片坯料(1)Polycrystallinediamondcompact(PDC)Selectandusedomesticrawmaterials,andaftertheproceduresofre-coining,purification,purging,burdeningandassembling,useadvancedultrahighpressure-hightemperaturesynthesistechnologytoproducepolycrystallinediamondcompact(PDC)billetonthedomesticcubic(hydraulic)press.聚晶金剛石復(fù)合片具體生產(chǎn)工藝簡述：根據(jù)訂單和公司計(jì)劃下達(dá)生產(chǎn)任務(wù)單；原料、輔料的購置；整形：對(duì)金剛石的形狀進(jìn)行嚴(yán)格控制，對(duì)所購原料進(jìn)行重新整形，盡量去除長條形等不規(guī)則形狀的金剛石顆粒，獲得圓度好的、基本上為球形的金剛石顆粒；Introductionofthespecificproductiontechnologyofpolycrystallinediamondcompact(PDC):Assignproductiontasksinaccordancewiththeordersandcompanyplan;Purchaserawmaterialsandauxiliarymaterials;Coining:strictlycontrolthediamondshape,re-cointhepurchasedrawmaterials,anddothebesttoeliminatethediamondparticleswithirregularshapessuchasstriponestoobtaindiamondparticleswithgoodroundnessandwhicharebasicallyspherical.分級(jí)：將混合粉料放入燒杯中，加入超凈化去離子水，攪拌混合均勻，根據(jù)不同粒度沉降時(shí)間不同的原理選取所需粒度，使用激光粒度分析儀對(duì)粒度的分布進(jìn)行精確測量；凈化：對(duì)金剛石微粉、鈷粉及其他原料進(jìn)行氫氣還原處理；氫氣還原處理工藝：在氫氣還原爐中處理，依據(jù)材料的不同選擇不同的處理溫度，大致范圍為500-800°C；Classification:putthemixedpowderintothebeaker,addsuper-purgativedeionizedwater,stirandmixitevenly,selectrequiredparticlesizeinaccordancewiththesettlingtimetheoryofdifferentparticlesizes,andusethelaserparticlesizeanalyzertoaccuratelymeasurethedistributionofparticlesizes;Purification:performhydrogenreductivetreatmenttodiamondmicro-powder,cobaltpowderandotherrawmaterials;hydrogenreductivetreatmenttechniques:processitinthehydrogenreducingfurnace,selectdifferenttreatmenttemperaturesinaccordancewithdifferentmaterials,andtheproximaterangeshouldbebetween500-800C;6）配料：按照一定的比例將金剛石與鈷粉、以及少量的微量元素進(jìn)行混合，其中金剛石的粒度嚴(yán)格控制，強(qiáng)調(diào)平均粒度以及不同粒度的配合比例。所配原料在球磨機(jī)中進(jìn)行充分混合，嚴(yán)格控制球磨時(shí)間和球磨機(jī)轉(zhuǎn)速；：對(duì)于大尺寸聚晶金剛石切割刀片在裝料時(shí)，要采取特定的裝料方式以保證復(fù)合片中聚晶金剛石層的厚度的均勻性；。對(duì)于聚晶立方氮化硼切割刀片，工序中需將金剛石微粉改換為氮化硼微粉、C。等原料，改為合適的粘結(jié)劑粉末(鋁、氮化鋁、氮化鈦等各種粉末)；Burdening:mixthediamond,cobaltpowdeandasmallamountofmicroelementsinaccordancewithacertainproportion,ofwhichthediamondparticlesizesshouldbeunderstrictcontrol,andthemixtureratioofaverageparticlesizeanddifferentparticlesizesshouldbeemphasized.Adequatelymixtheburdenedrawmaterialsintheballmill,andstrictlycontroltheballmillingtimeandtherotatingspeedoftheballmill;whenloadingbig-sizepolycrystallinediamondcuttingblades,specialloadingmethodshouldbeadoptedtoensureeventhicknessofthepolycrystallinediamondlayerinthecompact;forthepolycrystallinecubicboronnitride(PCBN)cuttingblades,duringtheprocedure,changethediamondmicro-powderintomaterialslikeboronnitridemicro-powderandCo,andchangeitintoappropriatebinderpowder(suchasvariouspowderslikealuminium,aluminiumnitrideandtitaniumnitride).組裝:在200t油壓機(jī)上壓制近似于立方體的葉蠟巖塊;將球磨好的原料在真空度為10-3Pa的情況下進(jìn)行真空熱處理，冷卻出爐后盡快將原料放入鉬杯中并用鉬蓋蓋好;合成:根據(jù)合成聚晶金剛石復(fù)合片的尺寸選擇合適噸位的六面頂壓機(jī)進(jìn)行超高壓高溫合成。如果需要合成大尺寸的聚晶金剛石復(fù)合片，需選用大噸位的六面頂壓機(jī)，針對(duì)部分產(chǎn)品及工藝的特殊要求，有時(shí)需要使用目前國內(nèi)最大的20000噸六面頂壓機(jī)。所需溫度為1500-1800°C,壓力最大保持6GPa。該步驟是整個(gè)工序中最重要的部分，也是技術(shù)的核心，必須優(yōu)化工藝參數(shù)以達(dá)到最優(yōu)化的合成工藝。產(chǎn)品種類、規(guī)格不同，合成所用參數(shù)需要調(diào)節(jié)；PCBN合成時(shí)，合成方法與合成聚晶金剛石刀片的方法相同，但工藝參數(shù)依據(jù)氮化硼含量和粘結(jié)劑含量、種類的不同而有較大的不同。Assembling:pressthepyrophylliteblockswithcubicshapesonthe200toilhydraulicpress;performvacuumheattreatmenttotheballmilledmaterialsunderavacuumdegreeof10-3Pa,putthematerialintothemolybdenumcupassoonaspossibleafterdischargeandcooling,andcoveritwellwithamolybdenumcap;Synthesis:chooseacubicpressofappropriatetonnageinaccordancewiththesizeofPDCtoperformsuperhighpressure-hightemperaturesynthesis.Synthesisofbig-sizePDCrequirescubicpressofbigtonnage,andsometimesthecurrentbiggestdomesticcubicpressof20,000tonageisneededinaccordancewithspecialtechnologicalrequirementsofsomeproductsandprocedures.Requiredtemperatureis1500-1800C,andthebiggestpressureis6GPa.Thisstepisthemostimportantpartinthewholeprocedureaswellascoreofthetechnology,andtechnologicalparametersmustbeoptimizedtogenerateoptimizedsynthesistechnology.Parametersusedinthesynthesisneedtobeadjustedinaccordancewithdifferentproductcategoriesandsizes;whensynthesizingPCBN,themethodisthesamewiththesynthesisofpolycrystallinediamondcuttingblades,buttherearemajordifferencesoftechnologicalparametersinaccordancewithdifferentcontentsandcategoriesofboronnitrideandbinder.噴砂：合成后的產(chǎn)品在葉蠟巖塊中，首先去除葉蠟巖塊和包覆的鉬杯，之后進(jìn)行噴砂處理，除去加工合成過程中和去除葉蠟巖塊和鉬杯時(shí)黏附的氧化物、葉蠟巖等，露出產(chǎn)品坯料；磨外圓：對(duì)產(chǎn)品坯料用外圓磨床磨外圓。由于超高壓高溫合成過程中原料會(huì)發(fā)生流動(dòng)，所獲得的產(chǎn)品坯料形狀不完美，達(dá)不到產(chǎn)品外觀要求，需要通過磨外圓，得到完美的圓柱體，同時(shí)，通過磨外圓控制樣品的尺寸(直徑)；Sandblast:thesynthesizedproductisinthepyrophylliteblock.Firstremovethepyrophylliteblockandcoveredmolybdenumcup,andthenperformsandblasttreatmenttoremoveadheredoxideandpyrophyllitefromthesynthesisprocessandremovalofthepyrophylliteblockandmolybdenumcuptoexposetheproductbillet;Externalgrinding:usethecylindricalgrindertoperformexternalgrindingtotheproductbillet.Becausethematerialmayhavefluctuatedduringthesuperhighpressure-hightemperaturesynthesis,sotheobtainedproductmaynothaveaperfectshapeandmeettherequirementofproductappearance,andaperfectylinderhastobeobtainedthroughexternalgrinding.Inthemeantime,externalgrindingcanalsobeusedtocontrolthesizethesample(diameter);研磨：主要采用電火花進(jìn)行平面切削這一突破性工藝，以減少單純研磨所造成的工序所需時(shí)間很長，所消耗的金剛石磨料量大的缺陷；當(dāng)電火花切削產(chǎn)品坯料接近所需尺寸時(shí)，再采用高精度雙面研磨機(jī)研磨到所需尺寸(厚度)；平磨倒角：倒角大小約0.1-0.5mm，角度45；刀片可能需要根據(jù)用戶要求分割為大小和形狀不同的切割片Grinding:electricdischargemachine(EDM)ismainlyadoptedtoperformthebreakthroughtechnologyoffacecuttingtoovercomethedefectsoflongprocesstimeandbigamountofabrasivematerialsduringthepuregrinding;afterusingtheelectricdischargemachine(EDM)tocuttheproductbilletclosetotherequiredsize,thenusethehigh-precisiondouble-facedgrindingmachinetogrinditintotherequiredsize(thickness);Chamferofflatgrinding:thechamfershouldbeabout0.1-0.5mmwithanangleof45;thebladescanbedividedintocuttingbladesofdifferentsizesandshapesinaccordancewiththecustomerrequirement;成品檢驗(yàn)：產(chǎn)品按照公司以及產(chǎn)品使用廠家的技術(shù)要求進(jìn)行外觀、尺寸(包括尺寸公差、平整度、表面缺陷、機(jī)械損傷以及長時(shí)間存放時(shí)腐蝕程度)、物理性能等項(xiàng)目的檢驗(yàn)，進(jìn)行分級(jí)，合格后裝箱。這是保證產(chǎn)品質(zhì)量的重要步驟；在成品檢測過程中更強(qiáng)調(diào)聚晶金剛石的厚度的測定包裝裝箱：出廠的產(chǎn)品外觀、尺寸必須能達(dá)到國外同類著名公司產(chǎn)品同樣的標(biāo)準(zhǔn)，同時(shí)要保證產(chǎn)品經(jīng)長途運(yùn)輸(特別是國外用戶)，產(chǎn)品外觀、尺寸不會(huì)變化；入庫：經(jīng)檢驗(yàn)合格的產(chǎn)品須按不同品種、規(guī)格、等級(jí)等分門別類進(jìn)行入庫儲(chǔ)存。Productinspection:inaccordancewithtechnicalrequirementsofthecompanyandcustomer,inspectionofitemssuchasappearance,dimensions(includingdimensionaltolerances,flatness,sur