Full-tool-bit ultrathin diamond composite material and preparation method thereof

Abstract

The invention discloses a full-tool-bit ultrathin diamond composite material and a preparation method thereof, and belongs to the technical field of diamond saw blades. The composite material comprises the following materials in parts by weight: 20-30 parts of cobalt powder, 10-20 parts of copper powder, 8-12 parts of nickel powder, 10-15 parts of tin powder, 10-15 parts of copper-phosphorus alloy powder, 8-12 parts of iron-copper alloy powder, 5-10 parts of copper-tin alloy powder, 5-10 parts of ferrophosphorus powder and 18-22 parts of diamond powder. The bending strength of the prepared ultra-thin diamond composite material semi-finished product is stabilized at the high level larger than or equal to 3.5 N.m and far exceeds the industrial safety standard. And subsequently, flexible laser cutting can be carried out according to requirements to obtain different outer diameters, and edging is carried out for use. When being used for cutting materials with high hardness and high brittleness, the product has the comprehensive advantages of high cutting speed, long service life, good cutting surface quality, difficulty in edge breakage and the like, and meets the requirements of the high-end precision machining field on ultrathin cutting tools.

Description

Technical Field

[0001] This invention belongs to the field of diamond saw blade technology, specifically relating to an ultra-thin diamond composite material with a full-tip blade and its preparation method. Background Technology

[0002] Diamond saw blades are widely used for cutting hard and brittle materials such as stone, ceramics, glass, and semiconductors due to their extremely high hardness and wear resistance. With the development of precision manufacturing and micromachining technologies, the market has placed higher demands on the thickness, precision, and surface quality of cutting tools, leading to a growing demand for ultra-thin diamond saw blades.

[0003] Existing technologies for manufacturing ultrathin diamond saw blades face the following challenges: First, while ensuring an ultrathin thickness (typically less than 1.0 mm), it is difficult to maintain sufficient bending strength and overall toughness of the blade tip, making it prone to cracking or deformation during cutting, posing safety hazards. Second, traditional matrix formulations lack sufficient holding power for diamonds, or improper sintering processes can easily lead to premature detachment of diamond particles during high-speed cutting, resulting in short tool life. Third, single-size diamond formulations cannot simultaneously achieve high cutting efficiency and good surface finish, affecting processing quality.

[0004] Therefore, there is an urgent need to develop a new composite material formulation and a matching preparation process to solve the problem of balancing strength, wear resistance and cutting accuracy in ultra-thin structures. Summary of the Invention

[0005] In view of this, the purpose of this invention is to provide an ultra-thin diamond composite material with a full cutting head and its preparation method. When cutting materials with high hardness and high brittleness, the product of this invention exhibits comprehensive advantages such as fast cutting speed, long service life, good cut surface quality, and less edge chipping.

[0006] To achieve the above objectives, the present invention provides the following technical solution: In a first aspect, the present invention provides an ultra-thin diamond composite material for the entire cutting head, comprising the following parts by weight: 20-30 parts cobalt powder, 10-20 parts copper powder, 8-12 parts nickel powder, 10-15 parts tin powder, 10-15 parts copper-phosphorus alloy powder, 8-12 parts iron-copper alloy powder, 5-10 parts copper-tin alloy powder, 5-10 parts phosphorus-iron powder, and 18-22 parts diamond powder.

[0007] Preferably, the raw materials are in the following weight proportions: 25 parts cobalt powder, 15 parts copper powder, 10 parts nickel powder, 13 parts tin powder, 12 parts copper-phosphorus alloy powder, 10 parts iron-copper alloy powder, 8 parts copper-tin alloy powder, 7 parts phosphorus-iron powder, and 20 parts diamond powder.

[0008] In this invention, cobalt powder serves as the core framework metal, providing high strength, high wear resistance, and good holding power. Copper powder acts as the base binder metal, ensuring good formability and thermal conductivity of the matrix. Nickel powder is an auxiliary reinforcing metal, enhancing the toughness and heat resistance of the matrix. Tin powder, a low-melting-point metal, generates a liquid phase during sintering, promoting densification. Copper-phosphorus alloy powder, as a sintering aid, lowers the sintering temperature and improves diamond wetting. Iron-copper alloy powder has a stable composition, contributing to improved matrix uniformity and hardness. Copper-tin alloy powder allows for more precise control of the formation and distribution of low-melting-point phases. Phosphorus-iron powder provides iron (Fe) and phosphorus (P) elements and is often used as a deoxidizer and alloy reinforcing phase.

[0009] Preferably, the diamond powder has the following mass composition: Model 2180: 30% diamond powder of 60 / 70 mesh; Model 2180: 40% diamond powder of 70 / 80 mesh; Model 2160: 30% diamond powder of 80 / 100 mesh.

[0010] In the diamond abrasive formulation of this invention, the 2180 grade, 60 / 70 mesh, provides the main cutting force and cutting efficiency. The 2180 grade, 70 / 80 mesh, serves as an intermediate grit size, balancing cutting efficiency and surface finish. The 2160 grade, 80 / 100 mesh, provides a finer grinding action, improving the surface quality of the machined workpiece.

[0011] This invention also provides a method for preparing the above-mentioned full-tip ultrathin diamond composite material, comprising the following steps: S1. Weigh the raw materials, and then mix the raw materials with liquid paraffin evenly to obtain a premix; S2. The premixed material is placed in a mold for cold pressing, hot pressing and sintering, inspection, and tempering and leveling to obtain an ultra-thin diamond composite material with a full blade tip.

[0012] Preferably, the amount of white oil added in S1 is 0.3% of the total weight of the raw materials.

[0013] Preferably, the pressure for cold pressing in S2 is 25-45 tons.

[0014] Preferably, the hot pressing sintering pressure in S2 is 20KN and the sintering temperature is 800-900℃.

[0015] Preferably, the bending strength tested in S2 is ≥3.5 NM.

[0016] Preferably, the specific method for tempering and leveling in S2 is as follows: the surface release agent is removed by washing in hot water at 90°C, and then the surface is flattened and stacked on a carbon plate, and tempered and leveled at 800°C.

[0017] It contains at least the following beneficial technical effects: The ultrathin diamond composite material semi-finished product prepared by this invention exhibits a high flexural strength of ≥3.5 N·m, far exceeding industry safety standards. It can be flexibly laser-cut into different outer diameters (25-60 mm) according to requirements and then sharpened before use. When cutting materials with high hardness and brittleness, the product demonstrates comprehensive advantages such as fast cutting speed, long lifespan, good cut surface quality, and resistance to edge chipping, meeting the needs of high-end precision machining fields for ultrathin cutting tools. Detailed Implementation

[0018] Various exemplary embodiments of the present invention will now be described in detail. This detailed description should not be considered as a limitation of the present invention, but rather as a more detailed description of certain aspects, features, and embodiments of the present invention.

[0019] It should be understood that the terminology used in this invention is merely for describing particular embodiments and is not intended to limit the invention. Furthermore, with respect to numerical ranges in this invention, it should be understood that each intermediate value between the upper and lower limits of the range is also specifically disclosed. Every smaller range between any stated value or intermediate value within a stated range, and any other stated value or intermediate value within said range, is also included in this invention. The upper and lower limits of these smaller ranges may be independently included or excluded from the range.

[0020] Unless otherwise stated, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. While only preferred methods and materials have been described herein, any methods and materials similar or equivalent to those described herein may be used in the implementation or testing of this invention. All references to this specification are incorporated by way of citation to disclose and describe methods and / or materials associated with those references. In the event of any conflict with any incorporated reference, the content of this specification shall prevail.

[0021] Various modifications and variations can be made to the specific embodiments described in this specification without departing from the scope or spirit of the invention, as will be apparent to those skilled in the art. Other embodiments derived from this specification will also be obvious to those skilled in the art. This application specification and embodiments are merely exemplary.

[0022] The terms “include,” “including,” “have,” “contain,” etc., used in this article are all open-ended terms, meaning that they include but are not limited to.

[0023] Unless otherwise specified, "room temperature" and "normal temperature" in this invention refer to 25±2℃.

[0024] Unless otherwise specified, all raw materials or instruments used in the following embodiments of the present invention are commercially available.

[0025] Example 1 This embodiment provides a method for preparing an all-tip ultrathin diamond composite material: Formula: Weigh the following raw materials: 20 parts cobalt powder, 10 parts copper powder, 8 parts nickel powder, 10 parts tin powder, 10 parts copper-phosphorus alloy powder, 8 parts iron-copper alloy powder, 5 parts copper-tin alloy powder, 5 parts phosphorus-iron powder, and 18 parts diamond powder. The diamond powder is composed of 30% 2180 type 60 / 70 mesh powder, 40% 2180 type 70 / 80 mesh powder, and 30% 2160 type 80 / 100 mesh powder.

[0026] preparation: Mixing: Mix all the weighed powders with 0.3% of the total powder weight of liquid paraffin, place them in a three-dimensional mixer and mix for 60 minutes to obtain a uniform premix.

[0027] Cold pressing: The premixed material is put into the mold and cold pressed under a pressure of 25 tons to obtain a blank of the specified size.

[0028] Hot pressing sintering: The pressed blank is placed into a hot pressing mold and then placed in a sintering furnace. Argon gas is introduced as a protective gas, and the blank is sintered at 800℃ and 20KN pressure per column for 5 hours, followed by furnace cooling.

[0029] Inspection and reheating: The sintered billet is inspected and its bending strength meets the standard (≥3.5 N·m). It is then washed in hot water at 90℃, placed on a flat carbon plate, and tempered and leveled at 800℃ to obtain a semi-finished product.

[0030] Performance: The resulting composite material has a thickness of 0.6 mm and a bending strength of 3.6 N·m. When used to cut alumina ceramics, it produces a smooth cut surface without chipping and has a long tool life.

[0031] Example 2 This embodiment provides an ultra-thin diamond composite material with a full-tip blade and its preparation method.

[0032] Formula: Weigh the following raw materials: 25 parts cobalt powder, 15 parts copper powder, 10 parts nickel powder, 13 parts tin powder, 12 parts copper-phosphorus alloy powder, 10 parts iron-copper alloy powder, 8 parts copper-tin alloy powder, 7 parts phosphorus-iron powder, and 20 parts diamond powder. The diamond particle size distribution is the same as in Example 1.

[0033] preparation: Mixing: Mix all the weighed powders with 0.3% of the total powder weight of liquid paraffin, place them in a three-dimensional mixer and mix for 60 minutes to obtain a uniform premix.

[0034] Cold pressing: The premixed material is put into the mold and cold pressed under a pressure of 35 tons to obtain a blank of the specified size.

[0035] Hot pressing sintering: The pressed blank is placed into a hot pressing mold and then placed in a sintering furnace. Argon gas is introduced as a protective gas, and the blank is sintered at 800℃ and 20KN pressure per column for 5 hours, followed by furnace cooling.

[0036] Inspection and reheating: The sintered billet is inspected and its bending strength meets the standard (≥3.5 N·m). It is then washed in hot water at 90℃, placed on a flat carbon plate, and tempered and leveled at 800℃ to obtain a semi-finished product.

[0037] Performance: The resulting composite material has a thickness of 0.6mm and excellent bending strength. It is used for precision cutting of single-crystal silicon wafers, offering high cutting efficiency, shallow surface scratches, and significantly longer tool life compared to similar ultra-thin products on the market.

[0038] Example 3 This embodiment provides an ultra-thin diamond composite material with a full-tip blade and its preparation method.

[0039] Formula: Weigh the following raw materials: 30 parts cobalt powder, 20 parts copper powder, 12 parts nickel powder, 15 parts tin powder, 15 parts copper-phosphorus alloy powder, 12 parts iron-copper alloy powder, 10 parts copper-tin alloy powder, 10 parts phosphorus-iron powder, and 22 parts diamond powder. The diamond particle size distribution is the same as in Example 1.

[0040] preparation: Mixing: Mix all the weighed powders with 0.3% of the total powder weight of liquid paraffin, place them in a three-dimensional mixer and mix for 60 minutes to obtain a uniform premix.

[0041] Cold pressing: The premixed material is put into the mold and cold pressed under a pressure of 35 tons to obtain a blank of the specified size.

[0042] Hot pressing sintering: The pressed blank is placed into a hot pressing mold and then placed in a sintering furnace. Argon gas is introduced as a protective gas, and the blank is sintered at 800℃ and 20KN pressure per column for 5 hours, followed by furnace cooling.

[0043] Inspection and reheating: The sintered billet is inspected and its bending strength meets the standard (≥3.5 N·m). It is then washed in hot water at 90℃, placed on a flat carbon plate, and tempered and leveled at 800℃ to obtain a semi-finished product.

[0044] Performance: The resulting composite material has a thickness of 0.7mm and exhibits extremely high matrix hardness and wear resistance. When used for cutting high-hardness granite, it provides a sharp and durable cut, demonstrating exceptional durability.

[0045] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A full-tip ultrathin diamond composite material, characterized in that, The materials include the following parts by weight: 20-30 parts cobalt powder, 10-20 parts copper powder, 8-12 parts nickel powder, 10-15 parts tin powder, 10-15 parts copper-phosphorus alloy powder, 8-12 parts iron-copper alloy powder, 5-10 parts copper-tin alloy powder, 5-10 parts phosphorus-iron powder[1], and 18-22 parts diamond powder.

2. The ultra-thin diamond composite material with a full-tip cutting edge according to claim 1, characterized in that, The raw materials are in the following weight proportions: 25 parts cobalt powder, 15 parts copper powder, 10 parts nickel powder, 13 parts tin powder, 12 parts copper-phosphorus alloy powder, 10 parts iron-copper alloy powder, 8 parts copper-tin alloy powder, 7 parts phosphorus-iron powder, and 20 parts diamond powder.

3. The full-tip ultrathin diamond composite material according to any one of claims 1-2, characterized in that, The mass composition of the diamond powder is as follows: Model 2180: 30% diamond powder of 60 / 70 mesh; Model 2180: 40% diamond powder of 70 / 80 mesh; Model 2160: 30% diamond powder of 80 / 100 mesh.

4. The preparation method of the full-tip ultrathin diamond composite material according to claim 3, characterized in that, Includes the following steps: S1. Weigh the raw materials, and then mix the raw materials with liquid paraffin evenly to obtain a premix; S2. The premixed material is placed in a mold for cold pressing, hot pressing and sintering, inspection, and tempering and leveling to obtain an ultra-thin diamond composite material with a full blade tip.

5. The preparation method according to claim 4, characterized in that, The amount of white oil added in S1 is 0.3% of the total weight of the raw materials.

6. The preparation method according to claim 4, characterized in that, The pressure for cold pressing in S2 is 25-45 tons.

7. The preparation method according to claim 4, characterized in that, The hot pressing sintering pressure in S2 is 20KN, and the sintering temperature is 800-900℃.

8. The preparation method according to claim 4, characterized in that, The bending strength tested in S2 is ≥3.5 NM.

9. The preparation method according to claim 4, characterized in that, The specific method for tempering and leveling in S2 is as follows: the surface release agent is removed by cleaning in hot water at 90°C, and then the surface is flattened and stacked on a carbon plate, and tempered and leveled at 800°C.