The manufacturing process of PCD (Polycrystalline Diamond) milling cutters is a complex and delicate process, and the following are the main steps and characteristics of its manufacturing process in LINKUT company:

1、 Manufacturing of PCD composite chips

PCD composite sheet is the core part of PCD milling cutter, which is sintered from natural or artificially synthesized diamond powder and binder (such as cobalt, nickel and other metals) in a certain proportion at high temperature  and high pressure. During the sintering process, diamond crystals form bonding bridges mainly composed of TiC, SiC, Fe, Co, Ni, etc. The diamond crystals are embedded in the framework of the bonding bridges in the form of covalent bonds. PCD composite chips are usually made into disks with fixed diameters and thicknesses, which require grinding, polishing, and other corresponding physical and chemical treatments.

2、 Processing of PCD blades

The processing of PCD blades mainly includes the cutting of composite pieces, welding of blades, and grinding of blade edges

1）Cutting of composite sheets
Due to the high hardness and wear resistance of PCD composite sheets, special processing techniques must be used for cutting. Common processing methods include wire electrical discharge machining, laser processing, ultrasonic processing, and high-pressure water jet. Among them, electrical discharge machining has the best effect. It uses highly concentrated pulse discharge energy and strong discharge explosive force to melt the metal in PCD material, partially graphitize and oxidize some diamonds, and partially detach some diamonds, thus forming the desired shape.

2）Welding of blades
The bonding between PCD composite pieces and the blade body is usually achieved by brazing the PCD composite pieces onto a hard alloy substrate. The main welding methods include laser welding, vacuum diffusion welding, vacuum brazing, and high-frequency induction brazing. Among them, high-frequency induction heating brazing has been widely used in PCD blade welding due to its low investment and cost. The selection of welding temperature, flux, and welding alloy during the welding process will directly affect the performance of the tool after welding.

3）Blade grinding
The PCD tool grinding process mainly uses ceramic bonded diamond grinding wheels for grinding. Due to the interaction between two materials with similar hardness, the grinding law between grinding wheel abrasive and PCD is relatively complex. For high granularity and low-speed grinding wheels, using water-soluble coolant can improve the grinding efficiency and accuracy of PCD. The selection of grinding wheel binder should depend on the type of grinder and processing conditions. In addition, electric discharge grinding (EDG) technology has significant advantages in grinding PCD because it is almost unaffected by the hardness of the workpiece being ground.

3、 Forming and polishing of PCD milling cutters

After completing the machining of PCD blades, it is also necessary to carry out the forming and polishing work of PCD milling cutters. This usually involves installing the PCD blade onto the cutter body, ensuring the dimensional accuracy and surface quality of the PCD milling cutter through precision machining and polishing processes.

In summary, the manufacturing process of PCD milling cutters is a complex and sophisticated process involving multiple links and various technologies. By continuously optimizing manufacturing processes and improving technological levels, the performance and quality of PCD milling cutters can be further enhanced to meet the modern manufacturing industry's demand for high-precision and high-efficiency machining.