| Diamond used as the known hardest material in nature with high strength, wear resistance and excellent physical and chemical properties. Diamond tools are made with diamond cutting material, and it has excellent performance, especially in optical glass, semiconductors, jade, stone and hard brittle difficult to cut materials. Diamond tools are widely used in many aspects, such as aviation, aerospace, automotive, electronics, ceramics and construction. It plays an important role in promoting the industrial development. With the development of the society, the demanding for precision diamond tools became more and more high. The research of manufacturing high precision diamond tools start relatively late in domestic and the research of mechanism is not enough. The problems of manufacturing precision and service life of sophisticated diamond tools are urgent to be solved. Therefore, carring out research to improve the level of manufacturing of precision diamond tools and promote the development of precision machining technology is of great significance.In this paper, through the study of manufacturing principles and manufacturing methods of precision diamond tools, we determined the internal electroplating method to manufacture diamond tools and studied the main process, precision diamond placing, the mechanical properties of the coating, the control of coating precision to get the scientific manufacturing methods and processes of the sophisticated diamond tools. The specific studies are as follows:1. The manufacturing methods research of high-precision diamond toolsThrough the analysis of internal electroplating, external electroplating and powder metallurgy method of precision diamond tools about the manufacturing principles, process characteristics and applications, We got the internal electroplating method to produce diamond tools has the highest manufacturing precision and complexity shape. The main process and features of internal electroplated diamond tools are discussed at last.2. Research on key technology of manufacture sophisticated diamond tools by internal electroplating method.(1)Research on precision diamond placing using internal electroplating method. Inter-sand method was determined to manufacture diamond tools by comparing the several sand placing method. The influence law of the sand placing on cathodic current density and time were studied. The results showed that diamond particle size50/60 for example, the sand places better when cathode current density 0.5A/dm2, 3 hours.(2)Effect of bath composition on mechanical properties of the diamond tool coating. Orthogonal experiment method was used to optimize the composition of the bath. The influence law of bath composition on mechanical properties were studied. The concentration of the optimum bath compositions were obtained by range method: nickel sulfate 270g/L, cobalt sulfate 20g/L, sodium chloride 10g/L.(3)Research on the effect of internal stress on precision of diamond tools. The theoretical analysis on the mechanism and the factors of the stress deposit were analyzed. The influence law of the main factors on coating precision was stuied. The results showed that the internal stress increases with the current density rises, the coating stress is less when the concentration of cobalt sulfate 10g/L, the bath temperature 50 ℃, the concentration of additive saccharin 1g/L.3. Project developed precision diamond tools and precision.Diamond tools were manufactured by internal electroplating method in the project, the Precision of the diamond tools are pitch error ±0.003 mm, circle radius error ±0.01 mm, contour Error 0.005 mm, diametrical dimension error ±0.003 mm, angle error ±5′, form error 0.006 mm, run-out error 0.004 mm. |
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