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History
In Natural History, Pliny wrote "When an adamas is
successfully broken it disintegrates into splinters so small as to be scarcely
visible. These are much sought after by engravers of gems and are inserted by
them into iron tools because they make hollows in the hardest materials without
difficulty.
Some examples of
diamond tools
Diamond dressing
tools
Diamond dressers consist of single-point or multipoint tools
brazed to a steel shank, and used for the trueing and dressing of grinding
wheels. The tools come in several types, including: grit impregnated, blade
type, crown type, and disc type. The advantages of multipoint over single-point
tools are:
The whole diamond can be used; in a single-point tool, when
the point is blunt the diamond must be reset, and after few resettings the
diamond is replaced.
Multipoint tools have higher accuracy, especially in form
grinding, where blade types are used. Blades consist of elongated diamonds. The
thickness is controlled and blades are available in thicknesses from 0.75 to
1.40 millimeters (0.030 to 0.055 in).
Grit-type tools are of a tough grade, and can be used for
bench grinders.
Since small points are used, the diamonds have a cutting
edge with natural points, unlike single-point tools, which have brutted points.
The cost of multipoint tools is lower, since smaller, less
expensive diamonds are used.
PCD cutting tools
Further information on synthetic diamond: Polycrystalline
diamond
Polycrystalline diamond (PCD) is formed in a large High
Temperature-High Pressure (HT-HP) press, as either a diamond wafer on a backing
of carbide, or forming a "vein" of diamond within a carbide wafer or
rod.
Most wafers are polished to a mirror finish, then cut with
an electrical discharge machining (EDM) tool into smaller, workable segments
that are then brazed onto the sawblade, reamer, drill, or other tool. Often
they are EDM machined and/or ground an additional time to expose the vein of
diamond along the cutting edge. These tools are mostly used for the machining
of nonmetallic and nonferrous materials.
The grinding operation is combined with EDM for several
reasons. For example, according to Modern Machine Shop,[citation needed] the
combination allows a higher material removal rate and is therefore more cost
effective. Also, the EDM process slightly affects the surface finish. Grinding
is used on the affected area to provide a finer final surface. The Beijing
Institute of Electro-Machining[citation needed] attributes a finer shaping and
surface geometry to the combination of the two processes into one.
The process itself is accomplished by combining the two
elements from each individual process into one grinding wheel. The diamond
graphite wheel accomplishes the task of grinding, while the graphite ring
around the existing wheel serves as the EDM portion. However, since diamond is
not a conductive material, the bonding in the PCD work piece must be ample
enough to provide the conductivity necessary for the EDG process to work.
Polycrystalline diamond tools are used extensively in
automotive and aerospace industries. They are ideal for speed machining (9000
surface feet per minute or higher) in tough and abrasive aluminum alloys, and
high-abrasion processes such as carbon-fiber drilling and ceramics. The diamond
cutting edges make them last for extended periods before replacement is needed.
High volume processes, tight tolerances, and highly abrasive processes are
ideal for diamond tooling.
Polycrystalline
diamond compacts
In the late 1970s, General Electric pioneered the technology
of polycrystalline diamond compacts (PDCs) as a replacement for natural
diamonds in drill bits. PDCs have been used to cut through crystalline rock
surfaces for extended periods of time in lab environments, and these
capabilities have now been implemented in harsh environments throughout the world.
As of August 2000, the U.S. Department of Energy claimed
that nearly one-third of the total footage drilled worldwide is being drilled
with PDC bits, with a claimed savings of nearly $100,000 per PDC bit as
compared to roller-core bits.
Diamond paste and
slurry
Diamond pastes are used for polishing materials that require
a mirror finish. They are often used in metallurgical specimens, carbide dies,
carbide seals, spectacle glass industry, and for polishing diamonds. Diamond
paste is mainly used in industrial requirements for polishing and sharpening
metal blades and other metal surfaces. The paste is not just to polish the
metal blade but sharpen the cutting edge as well.
Diamond electroplated
tools
Diamond powder deposited through electroplating is used to
make files (including nail files) and in small grinding applications.
Single point diamond
turning tools
Single point diamond turning (SPDT) utilizes a solid,
flawless diamond as the cutting edge. The single crystalline diamond can be natural
or synthetic, and is sharpened to the desired dimensions by mechanical grinding
and polishing. The cutting edge of most diamond tools is sharp to tens of
nanometers, making it very effective for cutting non-ferrous materials with
high resolution. SPDT is a very accurate machining process, used to create
finished aspherical and irregular optics without the need for further polishing
after completion. The most accurate machine tool in the world, the LODTM,
formerly at Lawrence Livermore National Laboratory, had a profile accuracy
estimated at 28 nm, while most machines seek a roughness within that deviation.
SPDT is used for optics, for flat surfaces where both
surface finish and unusually high dimensional accuracy are required, and when
lapping would be uneconomical or impractical.
Diamond saw blades
For high-speed gas powered cut-off saws, walk-behind saws,
handheld grinders, bridge saws, table saws, tile saws, and other types of saws.
Concave blade
Concave blade
For cutting curves in countertops to install sinks or sculpt
statues.
Tuck pointers
Thick diamond blades for restoration, involving grinding and
replacing mortar.
Crack chasers
Thick V-shaped diamond blades for repairing cracks in
concrete.
Diamond tipped
grinding cups
Typically used on hand grinders for grinding concrete or
stone.
Diamond tipped core
bit or holesaw
Hollow steel tube with diamond tipped segments for drilling
holes through concrete walls in the construction industry, porcelain tiles or
granite worktops in the domestic industry, or also used for sample core
extractions in the mining industry.
PCD tool insert
Used in machine tools for machining ceramics and high speed
aluminum.
PD tool insert
Used in turning centers for optics and precision surfaces.
Polishing pads
Pads with diamond crystals for polishing marble and other
fine stone.
Diamond wire cutting
Wire with diamond crystals for cutting.
Some of the features of Diamond Wire Cutting are:
Non-percussive, fumeless and quiet
Smooth cut face
Unlimited cutting depth
Horizontal, vertical and angled cutting of circular openings up to 2500mm diameter
Plunge cutting facility which allows blind and rebated openings to be formed
Remote controlled operation for increased safety
Some of the features of Diamond Wire Cutting are:
Non-percussive, fumeless and quiet
Smooth cut face
Unlimited cutting depth
Horizontal, vertical and angled cutting of circular openings up to 2500mm diameter
Plunge cutting facility which allows blind and rebated openings to be formed
Remote controlled operation for increased safety
Diamond saw chain
For cutting stone, concrete and brick with a special
chainsaw.
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