Diamond Sintered Material Composition for Crack-Resistant Cutting Tools
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Solution Overview
Problem
Conventional diamond sintered materials used in cutting tools suffer from breakage and crack progression issues, particularly under high-efficiency cutting processes, necessitating improved crack progressing resistance and tool durability.
Innovation Solution
A diamond sintered material with a diamond grain content ratio of 80-99% and average grain size of 0.1-50 μm, dislocation density of 1.2×10^16 to 5.4×10^19 m^-2, and a binder phase comprising specific metal and intermetallic compounds, enhancing crack progressing resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If diamond sintered material is used for cutting tools, then hardness and wear resistance are improved, but crack progressing resistance and breakage resistance are insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the dislocation density of diamond grains within 1.2×10^16 to 5.4×10^19 m^-2 and average grain size within 0.1 to 50 μm. This optimization of physical parameters resolves the contradiction by achieving both high hardness and improved crack progressing resistance through controlled dislocation structures that prevent crack propagation while maintaining diamond's inherent hardness
Solution Approach 2:
The patent uses composite materials by creating a sintered material composed of diamond grains bonded with binder phase containing specific metal elements (titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, or molybdenum) at 0.5-50 mass%. This composite structure combines the extreme hardness of diamond with the toughness and crack-resistant properties of the metal binder and carbide grains, resolving the contradiction between hardness and crack progressing resistance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The diamond sintered material exhibits excellent crack progressing resistance and improved breakage and impact resistance, suitable for cutting, wear-resistant, and grinding tools, particularly effective in milling and turning aluminum alloys.
Implementation Method 1
a dislocation density of the diamond grains is more than or equal to 1.2×10^16 m^-2 and less than or equal to 5.4×10^19 m^-2
Implementation Method 2
sintering a diamond powder, which is a source material, together with a sintering aid and a binder at high pressure and high temperature (generally, the pressure is about 5 to 8 GPa, and the temperature is about 1300 to 2200° C.)
Data Source
AI summary
A diamond sintered material includes diamond grains, wherein a content ratio of the diamond grains is more than or equal to 80 volume % and less than or equal to 99 volume % with respect to the diamond sintered material, an average grain size of the diamond grains is more than or equal to 0.1 μm and less than or equal to 50 μm, and a dislocation density of the diamond grains is more than or equal to 1.2×1016 m−2 and less than or equal to 5.4×1019 m−2.