聚晶金剛石復合片及其生產工藝簡述

聚晶金剛石復合片及其生產工藝簡述(1)聚晶金剛石復合片全部選用國產原材料，經過重新整形、提純、凈化、配料、組裝等工序，在國產六面頂(液)壓機上，采用先進的超高壓-高溫合成工藝，生產聚晶金剛石復合片坯料(1)Polycrystallinediamondcompact(PDC)Selectandusedomesticrawmaterials,andaftertheproceduresofre-coining,purification,purging,burdeningandassembling,useadvancedultrahighpressure-hightemperaturesynthesistechnologytoproducepolycrystallinediamondcompact(PDC)billetonthedomesticcubic(hydraulic)press.聚晶金剛石復合片具體生產工藝簡述：根據訂單和公司計劃下達生產任務單；原料、輔料的購置；整形：對金剛石的形狀進行嚴格控制，對所購原料進行重新整形，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：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，根據不同粒度沉降時間不同的原理選取所需粒度，使用激光粒度分析儀對粒度的分布進行精確測量；凈化：對金剛石微粉、鈷粉及其他原料進行氫氣還原處理；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行混合，其中金剛石的粒度嚴格控制，強調平均粒度以及不同粒度的配合比例。所配原料在球磨機中進行充分混合，嚴格控制球磨時間和球磨機轉速；：對于大尺寸聚晶金剛石切割刀片在裝料時，要采取特定的裝料方式以保證復合片中聚晶金剛石層的厚度的均勻性；。對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:根據合成聚晶金剛石復合片的尺寸選擇合適噸位的六面頂壓機進行超高壓高溫合成。如果需要合成大尺寸的聚晶金剛石復合片，需選用大噸位的六面頂壓機，針對部分產品及工藝的特殊要求，有時需要使用目前國內最大的20000噸六面頂壓機。所需溫度為1500-1800°C,壓力最大保持6GPa。該步驟是整個工序中最重要的部分，也是技術的核心，必須優(yōu)化工藝參數以達到最優(yōu)化的合成工藝。產品種類、規(guī)格不同，合成所用參數需要調節(jié)；PCBN合成時，合成方法與合成聚晶金剛石刀片的方法相同，但工藝參數依據氮化硼含量和粘結劑含量、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：合成后的產品在葉蠟巖塊中，首先去除葉蠟巖塊和包覆的鉬杯，之后進行噴砂處理，除去加工合成過程中和去除葉蠟巖塊和鉬杯時黏附的氧化物、葉蠟巖等，露出產品坯料；磨外圓：對產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)生流動，所獲得的產品坯料形狀不完美，達不到產品外觀要求，需要通過磨外圓，得到完美的圓柱體，同時，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間很長，所消耗的金剛石磨料量大的缺陷；當電火花切削產品坯料接近所需尺寸時，再采用高精度雙面研磨機研磨到所需尺寸(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：產品按照公司以及產品使用廠家的技術要求進行外觀、尺寸(包括尺寸公差、平整度、表面缺陷、機械損傷以及長時間存放時腐蝕程度)、物理性能等項目的檢驗，進行分級，合格后裝箱。這是保證產品質量的重要步驟；在成品檢測過程中更強調聚晶金剛石的厚度的測定包裝裝箱：出廠的產品外觀、尺寸必須能達到國外同類著名公司產品同樣的標準，同時要保證產品經長途運輸(特別是國外用戶)，產品外觀、尺寸不會變化；入庫：經檢驗合格的產品須按不同品種、規(guī)格、等級等分門別類進行入庫儲存。Productinspection:inaccordancewithtechnicalrequirementsofthecompanyandcustomer,inspectionofitemssuchasappearance,dimensions(includingdimensionaltolerances,flatness,sur