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〔液〕壓機(jī)上，承受先進(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：1〕依據(jù)訂單和公司打算下達(dá)生產(chǎn)任務(wù)單；原料、輔料的購置；規(guī)章外形的金剛石顆粒，獲得圓度好的、根本上為球形的金剛石顆粒；Introductionofthespecificproductiontechnologyofpolycrystallinediamondcompact(PDC):Assignproductiontasksinaccordancewiththeordersandcompanyplan;Purchaserawmaterialsandauxiliarymaterials;Coining:strictlycontrolthediamondshape,re-cointhepurchasedrawmaterials,anddothebesttoeliminatethediamondparticleswithirregularshapessuchasstriponestoobtaindiamondparticleswithgoodroundnessandwhicharebasicallyspherical.時間不同的原理選取所需粒度，使用激光粒度對粒度的分布進(jìn)展準(zhǔn)確測量；5〕凈化：對金剛石微粉、鈷粉及其他原料進(jìn)展氫氣復(fù)原處理；氫氣復(fù)原處理工藝：在氫氣復(fù)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500-800℃；Classification:putthemixedpowderintothebeaker,addsuper-purgativedeionizedwater,stirandmixitevenly,selectrequiredparticlesizeinaccordancewiththesettlingtimetheoryofdifferentparticlesizes,andusethelaserparticlesizeanalyzertoaccuratelymeasurethedistributionofparticlesizes;Purification:performhydrogenreductivetreatmenttodiamondmicro-powder,cobaltpowderandotherrawmaterials;hydrogenreductivetreatmenttechniques:processitinthehydrogenreducingfurnace,selectdifferenttreatmenttemperaturesinaccordancewithdifferentmaterials,andtheproximaterangeshouldbebetween500-800℃;度嚴(yán)格把握，強(qiáng)調(diào)平均粒度以及不同粒度的協(xié)作比例。所配原料Co等原料，改為適宜的粘結(jié)劑粉末〔鋁、氮化鋁、氮化鈦等各種粉末；Burdening:mixthediamond,cobaltpowdeandasmallamounofmicroelementsinaccordancewithacertainproportion,ofwhichthediamondparticlesizesshouldbeunderstrictcontrol,andthemixtureratioofaverageparticlesizeanddifferentparticlesizesshouldbeemphasized.Adequatelymixtheburdenedrawmaterialsintheballmill,andstrictlycontroltheballmillingtimeandtherotatingspeedoftheballmill;whenloadingbig-sizepolycrystallinediamondcuttingblades,specialloadingmethodshouldbeadoptedtoensureeventhicknessofthepolycrystallinediamondlayerinthecompact;forthepolycrystallinecubicboronnitride(PCBN)cuttingblades,duringtheprocedure,changethediamondmicro-powderintomaterialslikeboronnitridemicro-powderandCo,andchangeitintoappropriatebinderpowder(suchasvariouspowderslikealuminium,aluminiumnitrideandtitaniumnitride).200t油壓機(jī)上壓制近似于立方體的葉蠟巖塊10-3Pa的狀況下進(jìn)展真空熱處理，冷卻出爐后盡快將原料放入鉬杯中并用鉬蓋蓋好；。假設(shè)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)，針對局部產(chǎn)品及202301500-1800℃，壓力最大保持6GPa。該步驟是整個工序中最重要的局部，也是技術(shù)的核心，必需優(yōu)化工藝參數(shù)以到達(dá)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)整；PCBN合成時，合成方法與合成聚晶金剛石刀片的方法一樣，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.Requiredtemperatureis1500-1800℃,andthebiggestpressureis6GPa.Thisstepisthemostimportantpartinthewholeprocedureaswellascoreofthetechnology,andtechnologicalparametersmustbeoptimizedtogenerateoptimizedsynthesistechnology.Parametersusedinthesynthesisneedtobeadjustedinaccordancewithdifferentproductcategoriesandsizes;whensynthesizingPCBN,themethodisthesamewiththesynthesisofpolycrystallinediamondcuttingblades,buttherearemajordifferencesoftechnologicalparametersinaccordancewithdifferentcontentsandcategoriesofboronnitrideandbinder.，除去加工合成過程中和去除葉蠟巖塊和鉬杯時黏附的氧化物、葉蠟巖等，露出產(chǎn)品坯料；10〕磨外圓：對產(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發(fā)生流淌，同時，通過磨外圓把握樣品的尺寸〔直徑；Sandblast:thesynthesizedproductisinthepyrophylliteblock.Firstremovethepyrophylliteblockandcoveredmolybdenumcup,andthenperformsandblasttreatmenttoremoveadheredoxideandpyrophyllitefromthesynthesisprocessandremovalofthepyrophylliteblockandmolybdenumcuptoexposetheproductbillet;Externalgrinding:usethecylindricalgrindertoperformexternalgrindingtotheproductbillet.Becausethematerialmayhavefluctuatedduringthesuperhighpressure-hightemperaturesynthesis,sotheobtainedproductmaynothaveaperfectshapeandmeettherequirementofproductappearance,andaperfecylinderhastobeobtainedthroughexternalgrinding.Inthemeantime,externalgrindingcanalsobeusedtocontrolthesizethesample(diameter);研磨：主要承受電火花進(jìn)展平面切削這一突破性工藝，以削減單純研磨所造成的工序所需時間很長，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，再承受高精度雙面研磨機(jī)研磨到所需尺寸〔厚度；0.1-0.5mm，角度45；刀片可能需要依據(jù)用戶要求分割為大小和外形不同的切割片Grinding:electricdischargemachine(EDM)ismainlyadoptedtoperformthebreakthroughtechnologyoffacecuttingtoovercomethedefectsoflongprocesstimeandbigamountofabrasivematerialsduringthepuregrinding;afterusingtheelectricdischargemachine(EDM)tocuttheproductbilletclosetotherequiredsize,thenusethehigh-precisiondouble-facedgrindingmachinetogrinditintotherequiredsize(thickness);Chamferofflatgrinding:thechamfershouldbeabout0.1-0.5mmwithanangleof45;thebladescanbedividedintocuttingbladesofdifferentsizesandshapesinaccordancewiththecustomerrequirement;〔包括尺寸公差、平坦度、外表缺陷、機(jī)械損傷以及長時間存放時腐蝕程度分級，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14〕包裝裝箱：出廠的產(chǎn)品外觀、尺寸必需能到達(dá)國外同類著名公司產(chǎn)品同樣的標(biāo)準(zhǔn)，同時要保證產(chǎn)品經(jīng)長途運輸〔特別是國外用戶，產(chǎn)品外觀、尺寸不會變化；15〕入庫：經(jīng)檢驗合格的產(chǎn)品須按不同品種、規(guī)格、等級等分門別類進(jìn)展入庫儲存。Productinspection:inaccordancewithtechnicalrequirementsofthecompanyandcustomer,inspectionofitemssuchasappearance,dimensions(includingdimensionaltolerances,flatness,surfacedefect,mechanicaldamageandcorrosivede