**1. Introduction**
Hard and brittle materials are characterized by their high hardness and low toughness, making them difficult to deform without breaking. These materials are typically non-conductive or semi-conductive and include substances like stone, glass, silicon crystals, quartz, ceramics, and hard alloys. As technology and industry advance, the application of such materials has expanded significantly, leading to continuous improvements in their processing techniques. Among various methods used for cutting these materials, diamond-based cutting tools play a crucial role due to their exceptional performance.
Diamond, being the hardest natural material, is widely used in the cutting and processing of hard and brittle materials. Its superior properties make it ideal for applications such as cutting stones, ceramics, and other similar materials. In industries like construction and precision manufacturing, sawing is often the first step in the machining process, and the cost associated with this step can account for over 50% of the total processing expenses. Therefore, optimizing the efficiency and durability of diamond cutting tools is essential for reducing costs and improving productivity.
Various diamond-based cutting techniques exist, including circular saw blades, band saws, frame saws, and bead saws. While each method has its own specific use cases, they all share similar cutting and wear mechanisms. Understanding these mechanisms is vital for the proper design, manufacturing, and usage of diamond tools. Researchers around the world have extensively studied the cutting processes of granite using diamond tools, the wear behavior of these tools, and the energy consumption during the cutting process. Their findings have contributed significantly to the advancement of cutting technologies and have provided valuable theoretical guidance for tool development.
**2. Diamond Cutting Mechanism for Stone**
Diamond abrasives are typically manufactured into cutting tools through sintering or plating. The cutting process of diamond tools resembles that of grinding, but the mechanism differs from metal cutting due to the nature of hard and brittle materials like stone and ceramics. This complexity makes the study of the cutting process challenging.
Early research focused on the interaction between single diamond particles and stone. Experiments showed that under different conditions, the primary failure mode of rock during cutting is brittle fracture, although some plastic deformation may occur depending on the mineral composition. Over time, researchers have employed advanced techniques such as polarizing microscopes and scanning electron microscopes to observe surface morphology and crack propagation during cutting. Acoustic emission signals have also been used to assess the cutting status of rocks.
Despite these advancements, a unified understanding of the cutting mechanism of hard and brittle materials remains elusive. This lack of consensus highlights the need for further research to improve the efficiency and effectiveness of diamond cutting tools.
In modern manufacturing, tooling costs are relatively small compared to overall production costs. However, optimizing tool usage, increasing efficiency, and reducing processing time are critical for lowering overall expenses. This is where advanced machine tools, such as CNC grinders, come into play.
During our interactions with customers, we often hear that end-users demand higher precision and better tool performance. Traditional hand-made tools no longer meet today’s standards, especially when it comes to accuracy and complexity. Based on our experience selling over 140 machine tools in China, we’ve identified several key requirements from our clients.
First, tool runout must be strictly controlled. With the rise of high-speed milling, the runout of the tool’s circumference, end face, and arc should be within 0.005 mm. This ensures stability and reduces vibration, allowing for higher cutting speeds and feed rates. Adjustments to the tool’s geometry can also be made more effectively, such as using a larger rake angle for non-ferrous metals or an auxiliary rake angle for harder materials like cast iron.
Second, tool geometry must be optimized for multi-process operations. Modern machining demands composite tools that can replace multiple steps, reducing tool changes and saving time. This approach not only increases efficiency but also lowers inventory and management costs.
Walter Machine Tool Co., Ltd. has introduced a range of versatile tools tailored to market needs, including composite cutters, toroidal mills, and Christmas tree cutters. These tools are widely used in industries such as aerospace, metallurgy, mold making, and turbine manufacturing.
Additionally, strong technical support and ongoing R&D are essential. Walter, part of the Schleifring Group, has a solid reputation in international grinding technology. Our Jiangsu Wuxi subsidiary provides nationwide after-sales service, and we launched a customer demonstration center in Taicang, Jiangsu, in May 2006. This initiative supports regional sales and service efforts, ensuring our customers receive timely assistance.
By integrating cutting technology with advanced machine tools, we aim to help customers move from simple “tool sales†to comprehensive “processing solutions.†This shift not only enhances the potential of cutting technology but also strengthens the company’s competitive edge in the market.
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