Product Details

 

Since the 1970s, scientists and engineers all over the world have been researching and utilizing a highly advanced material called polycrystalline diamond (PCD). PCD is produced through a process of sintering that involves extremely high temperatures of up to 1400°C and equally intense pressures of 6GPa. This cutting-edge material has a superhard texture that makes it ideal for a wide range of applications.

Polycrystalline diamond proves to be more than just an engineering material; it emerges as a groundbreaking functional substance, embodying both advanced technology and enhanced efficiency. As our industrial and technological sectors continue to evolve, the widespread utilization of polycrystalline diamond becomes evident across various domains including modern industry, national defense, and high-tech fields. This stems from its remarkable attributes such as exceptional mechanical, thermal, chemical, acoustic, optical, and electrical properties.

 

CBN CNC blade (ferrous metal machining)

 

Modern cutting relies heavily on PCD tools, making them essential and irreplaceable. The significance of PCD tools is evident in several key areas:

(1) High speed cutting, high stability processing;

(2) Ultra-precision mirror processing;

(3) Dry cutting and clean processing.

 

 

(1) High hardness and wear resistance

Polycrystalline diamond boasts an incredible hardness of approximately 10000HV, making it the most durable artificial material worldwide. This level of hardness surpasses that of both engineering ceramics and cemented carbide by a large margin. Its exceptional abrasion resistance is second to none.

(2) Low coefficient of friction

Polycrystalline diamond has a lower coefficient of friction compared to other materials, specifically about half of that of cemented carbide. This characteristic brings several benefits during cutting operations. Firstly, the reduced coefficient of friction minimizes deformation and cutting force, resulting in more efficient and precise cutting processes. Additionally, it plays a crucial role in preventing the formation of built-up edge, which can negatively affect the quality of the machined surface. Consequently, the low coefficient of friction contributes to a smoother and less rough machined surface.

(3) High thermal conductivity

Polycrystalline diamond exhibits excellent thermal conductivity, surpassing silver and copper, and even outperforms ordinary cemented carbide. Consequently, it efficiently dissipates heat generated during cutting operations, resulting in significantly low cutting temperatures.

(4) High machining accuracy

Due to its low coefficient of thermal expansion and high modulus of elasticity, the polycrystalline diamond tool remains undistorted during the cutting process. This allows the tool to maintain its original parameters and retain sharpness for extended periods, resulting in high cutting accuracy. It also enables the reduction of cutting force and cutting temperature when using PCD tools for processing. As a result, the durability and cutting rate of the tool are enhanced, and a superior machined surface can be achieved.

 

 

Automotive and Aerospace

PCD tools stand out for their outstanding durability, lasting several times longer than cemented carbide tools. Working with PCD tools also guarantees stable dimensional machining accuracy and excellent workpiece surface roughness. These tools are primarily deployed in processing non-ferrous metals and non-metallic materials. They are also highly effective when machining Al2O3, alloys, ceramics, composites reinforced with diverse fibers and particles, plastics, rubbers, graphite, glass, wood, and other materials. The current market offers a wide range of PCD tools, including PCD woodworking saw blades, trimming knives, indexable blades, piston series knives, wheel knives, commutator knives, watch cases, jewelry knives, and a broad assortment of PCD welding turning knives and wok knives.

PCD Compound Tool (Hole Machining)

 

The application of PCD tools in the automotive field accounts for 60%. PCD tools are mainly used in the automotive field for machining engine piston skirts, pin holes, cylinder blocks, gearboxes, carburetors, etc. Due to the high silicon content of these component materials (more than 10%), and most of them are mass-produced in an assembly line, the service life of the tool is relatively high, and the carbide tool is difficult to do, while the durability of the diamond tool is the highest in the carbide tool. 10-50 times of that, it can ensure the dimensional stability of the parts, and can greatly improve the cutting speed, processing efficiency and surface quality of the workpiece.

 

Wood processing industry

At present, the widely used man-made panels have obvious differences from traditional wood. In a sense, synthetic panels are the concept of synthetic resin, and their processing process is also different from that of traditional wood. In particular, the development of man-made panels such as MDF, plywood, particle board and composite flooring has accelerated the demand for superhard tools, so that diamond tools have gradually replaced the position of traditional woodworking tools in the market. Among them, the Al2O3 on the outermost layer of the reinforced composite floor has a great influence on the wear of the cemented carbide tool, and the use of PCD tools can effectively solve this problem.

 

Generally, the cutting tool is easy to fluff when trimming and cutting the printed board, which affects the installation and positioning of various electrical components, and the entire printed board is also unsightly. Cemented carbide cutting tools have short service life, slow processing speed, low processing efficiency and poor processing accuracy when processing electrical printed boards. The multi-blade electric printed board cutter made of PCD material is not easy to wear, and the processing line speed is as high as 1500-2000m/s, so it has high processing efficiency and low processing cost, and is widely used.

 

Petroleum geological drilling industry

The polycrystalline diamond bit uses a sharp, highly wear-resistant, and self-sharpening polycrystalline diamond cutting block as the cutting element, so that it can achieve high footage (4-6 times that of the roller cone bit) under low drilling pressure (about 40kN) And high drilling speed (more than 2 times higher than the roller cone bit). It has higher safety than the roller cone bit, which can greatly improve the drilling efficiency and reduce the drilling cost. It has outstanding advantages in large sections of soft to medium hardness formations, especially in high-cost offshore drilling and ultra-deep wells and slimhole drilling, PCD bits have incomparable advantages over roller cone bits.

 

Wire mold

The wire drawing die is a very important die for various metal wire manufacturers (such as wire and cable factories, steel wire factories, welding rod and wire factories, etc.) to draw wire. The scope of application of the wire drawing die is very wide. It is mainly used for drawing linear difficult-to-process objects such as rods, wires, wires, and pipes. It is suitable for drawing processing of steel, copper, tungsten, equivalent metals, and alloy materials.

Pcd Wire Drawing Dies

 

When drawing copper wire with the same diameter, the service life of polycrystalline diamond die is 300-500 times that of cemented carbide die, and 80-100 times that of tungsten carbide die. When drawing molybdenum wire, its service life is only as long as hard alloy die. The service life of the polycrystalline diamond die is 50-80 times that of the cemented carbide die, while the life of the polycrystalline diamond die is 20-60 times that of the cemented carbide die when drawing carbon steel. In addition to the commonly used wire and cable drawing dies, polycrystalline diamond wire dies also include enameled wire dies for motors, electrical appliances, transformers, and precision inner lead dies for integrated circuits.

 

Glass cutting

As a glass cutting tool with excellent performance, the knife wheel made of polycrystalline diamond is mainly used for high-precision and high-quality cutting of liquid crystal glass in the electronics industry. At the same time, it can cut glass for construction and automobiles. Ideal replacement for alloy glass cutter wheels. The mandrel and cutter wheel are made of polycrystalline diamond, which has the advantages of high processing precision, wear resistance, good consistency, and has an extraordinary service life.

 

Gem processing

Compared with the traditional electroplated diamond grinding wheel, the application of polycrystalline diamond in this field has the most prominent advantage of long tool life. In many cases, the working layer of electroplated diamond tools is a single layer of diamond. When grinding high hardness jade, It will soon be worn out and lose its ability to work, while polycrystalline diamond completely overcomes this weakness and greatly improves processing efficiency.

Gemstone processing is a newly developed application field of polycrystalline diamond tools in recent years. The market prospect is very promising, which greatly expands the market of polycrystalline diamond. The hardness of this new polycrystalline diamond is lower than that used in drilling and other fields, and some special treatments have been made to adapt to gem processing.

 

 

Compared with cemented carbide, the tensile strength of polycrystalline diamond is only 70% of that of commonly used cemented carbide, but its hardness is 2.5 times that of cemented carbide. In this way, the polycrystalline diamond mold has more advantages than the cemented carbide mold.

The wire drawing die made of polycrystalline diamond has good wear resistance, uniform inner hole wear, strong impact resistance and high wire drawing efficiency. Therefore, at present, polycrystalline diamond molds are gradually being valued in the metal wire drawing industry.

 

Compared with cemented carbide dies, the use of PCD drawing die has the following obvious advantages:

1. High drawing efficiency

During the use of the wire drawing die, necessary maintenance is very important to the service life of the wire drawing die and the surface quality of the wire. It is usually recommended that customers maintain the polycrystalline diamond wire drawing die every 24 hours. Within 24 hours, the hole diameter of the polycrystalline diamond wire drawing die changes little, and the wire diameter change rate of the drawn wire is also very small. For the whole production process, the wire diameter compression rate of each wire drawing die is relatively stable, and the ratio of input to output is large.

2. Good wear resistance and long service life

The service life of the polycrystalline diamond wire drawing die is about 30-50 times that of the cemented carbide die, so that there is no need to stop frequently to replace the die during the drawing process. The aperture of the polycrystalline wire drawing die changes very little per unit time, and the size of the drawn wire changes little, which is very beneficial to the reel winding. Generally, the number of winding turns of the drawn wire is fixed. If the size of the finished wire becomes larger quickly, the number of winding turns will decrease relatively rapidly, which requires constant changes in the size of the reel, which is not conducive to the improvement of production efficiency.

3. Save raw materials

If you draw a wire with a metal-plated surface, the electroplating process does not stop during the drawing process, which will cause the thickness of the electroplating layer on the surface of the wire being electroplated to exceed the standard. Great waste, the more downtime the greater the waste. Using polycrystalline diamond molds can greatly reduce this waste.

4. Reduce labor intensity

Due to the long life of the polycrystalline diamond wire drawing die and slow expansion, it is not necessary to replace the die frequently, and it is not like using a cemented carbide wire drawing die that must always pay attention to the change of the wire size, which greatly reduces the labor intensity of the workers. A worker in the production process We can take care of 4-5 wire drawing machines.

 

 

Company Introduction

Anhui Liyuan Wire Drawing Dies Co,Ltd specializes in manufacturing Synthetic Polycrystalline Diamond Die, Natural Diamond Die, Imported polycrystalline Die, Tin-plated Die, Film-coating Die, Extrusion Die and Special-shaped Die. Besides, we also have the following derivatives: electric wire and cable, electrical alloy, electromagnetic wire, steel cord, King Kong wire bonding wire, tungsten wire, molybdenum wire, stainless steel wire and so on.

 

Our company has successively introduced the advanced production and inspection equipment from Norway “CONOPTLCA" and German “SCOB" company. Therefore, with such large technical capacity, sophisticated production equipment, perfect craftsmanship, rigorous quality control and modern management approaches, we can offer extremely high quality products to our customers, And our product quality is at the leading level at home and abroad.

 

Our company has accumulated rich production experience in long-term production practice, and our production is strictly in accordance with IS09002 international quality standard. We have advanced production equipment, strong technical force and stable product quality. In the fierce market competition, we will continue to increase investments in science and technology to improve product quality and the service system Our business philosophy is to dedicate first-class products and services to our customers, Sincerely thank the old and new users for your love for Liyuan, and we hope to cooperate with you sincerely.

 

Wire Drawing Dies Type.

â–ª Tungsten carbide die
â–ª Natural diamond wire cutting
â–ª Single crystal diamond mold
â–ª PCD drawing die
â–ª High crystalline diamond wire drawing die

 

 

http://www.ly-wiredrawing.com/