In China, the current tools used for machining cast iron are primarily cemented carbide tools and corundum (or silicon carbide) abrasive tools. However, these tools suffer from several drawbacks, including low processing efficiency, poor surface quality, and limited tool safety. Especially when dealing with wear-resistant cast iron or parts with a white mouth layer and sand layer, traditional tools struggle to perform effectively. Inspired by the design principles of Japan’s Reagan Company for diamond saw blades used in cast iron slicing, we have developed a range of diamond-based tools, such as diamond burrs and diamond drills. These tools are designed to meet the diverse requirements of cutting, slotting, grinding, and drilling operations on cast iron materials.
Compared to conventional tools, diamond tools offer significant improvements in terms of processing quality, service life, and efficiency. They also provide high performance, low consumption, and enhanced safety during operation.
**Technical Solution and Principle**
The diamond tools are manufactured using an electroplating (electroforming) process, resulting in a metal-bonded diamond tool. This method ensures strong adhesion between the diamond particles and the substrate while maintaining the structural integrity of the tool.
To address the challenges associated with cast iron materials and diamond tools, several key design and manufacturing issues were tackled:
1. **Bonding Strength Between Metal Plating and Substrate**
Cast iron machining often occurs in dry conditions without cooling, which can cause thermal stress and lead to cracking or delamination of the coating. To overcome this, the following strategies were implemented:
- The base material is made from low-expansion coefficient alloy steel, and the plating bath uses a main salt with a similar thermal expansion coefficient to reduce stress differences.
- A copper transition layer is applied before plating to enhance adhesion between the substrate and the coating.
- The substrate undergoes electrical activation to improve bonding.
- Different plating solutions are used in the sand plating and thickening plating stages to minimize internal stresses and prevent premature peeling.
2. **Processing Efficiency**
Diamond tools feature a micro-cutting surface covered with diamond particles, but clogged or dulled cutting edges can reduce efficiency. To solve this:
- High-quality coarse-grained diamond single crystals are used as cutting edges.
- The depth of diamond embedding is controlled to ensure an average edge height of more than 0.1 mm.
- Electroplating processes are optimized with solution circulation, filtration, and profiling anodes to improve uniformity and reduce defects like metal tumors.
3. **Safety Issues**
High-quality steel plates and a rational structural design help eliminate stress concentration points, preventing matrix cracking during use.
**Experiment and Application**
Based on the above principles, we have developed various diamond tools tailored for different applications:
1. **Diamond Saw Blade**
This product is ideal for cutting risers, cast pipes, and piston rings. The substrate is made of annealed alloy steel, and the cutting edge uses MBD12 grade diamond single crystals with a grain size of 40/45. Protective layers of RVD70/80 diamond crystals are added to both sides to prevent scratches.
**Testing Conditions:**
- Machine: Fixed cutter RC-16 type
- Power: 2.2KW
- Spindle speed: 1900r/min
- Workpiece: QT40-17, diameter 30mm, annealed hardness HB230
- Load: 2Kgf, no cooling
**Test Results:**
| Saw Blade Specifications | Cut-off Quantity | Consumption Time |
|--------------------------|------------------|------------------|
| 12 inches | 15 | — |
| 14 inches | 1 | 20 |
The tool lasts 50–80 times longer than a resin blade of the same size, offering convenience, high safety, and reduced labor intensity.
2. **Diamond Grinding Tool**
Designed for cleaning cast iron parts and removing flash and burrs. The body is made of cold-rolled steel, and the abrasives are MBD8 grade with a particle size of 40/456. It lasts 30–50 times longer than a resin grinding wheel and provides excellent safety.
3. **Diamond Drill**
Used for core drilling in special conditions, such as cast iron pipes. The body is made of 45 steel tubing, and the abrasive is MBD8 grade with a grain size of 40/456. It offers high efficiency and safety.
**Conclusion**
Through careful design and extensive testing, it has been proven that diamond tools with optimized technology can effectively machine cast iron materials. These tools demonstrate excellent performance, making them a superior alternative to traditional tools in various industrial applications.
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