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Rollomatic maintains its leadership position in the field of laser cutting ultra-hard materials by announcing a breakthrough in achieving the highest possible surface finishing in machining PCBN material. Rollomatic succeeded in producing a surface finish of Ra 48 nanometers (0.048 micrometer) on a primary relief of a profile insert in PCBN material.
The tests were performed on the LaserSmart® LS510 cutting and ablation machine with 5 interpolating CNC axes. A “super-mirror” finish is generally known to be around 100 nanometers which Rollomatic was able to cut in half.
These tests were performed at the Rollomatic showroom facility in Mundelein, IL, USA, without sacrificing on feedrates or cycle times. In particular, the process ensured that the integrity of the edge quality was fully maintained without compromise.
The verification and measuring process was carried out by a Bruker-Alicona EdgeMaster Optical 3- Dimensional Metrology Unit.
Fanuc high-speed robot for Rollomatic ShapeSmart® LS510 Round-shaft PCD profile tools automatic loading and unloading
This machine produces the sharpest corner radius in the PCD/CBN industry with a maximum radius on the cutting edge below 0.5 micron. In addition, a defined radius of 3, 6 and 9 microns can also be produced consistently. In addition to round-shaft tools, HSK63 shanks can also be accommodated on this machine.
The strategy for this machine is to offer a more cost-effective way and higher quality in the production of high-performance PCD polycrystalline diamond, CBN cubic boron nitride and CVD chemical vapor deposited cutting tools which traditionally require to be produced by a double process of spark erosion and polish grinding.
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Up to 4 times faster feedrates with identical edge and surface quality.
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3D machining of drill points and endmill cutting geometries.
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Process to sharpen the cutting edge of CVD or thick-film diamond coated cutting tools.
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Fine-laser cutting achieves a superfine cutting edge with a surface finish that is unachievable by grinding/EDM.
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Conventional grinding with diamond wheels will invariably “pull out” an entire PCD crystals, while laser cutting will “slice” through the crystal and leave a portion of the crystal in the matrix, thus providing a razor-sharp cutting edge, unattainable by EDM, EDG (electro-discharge) or grinding.
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Linear motion technology on all linear and rotary axes provides highly accurate trajectories for
the complex cutting paths.
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Continuous field testing has shown that sharper cutting edges and superior surface quality on
PCD tools deliver longer tool life and higher feed rates during machining.
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Laser ablation allows the freedom to optimize tool geometries.
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Manufacturing chip form geometries in PCD is easily performed by this machine using the ablation process as a cost-effective and powerful alternative to existing complicated and expensive conventional methods.
Related Glossary Terms
- chemical vapor deposition ( CVD)
chemical vapor deposition ( CVD)
High-temperature (1,000° C or higher), atmosphere-controlled process in which a chemical reaction is induced for the purpose of depositing a coating 2µm to 12µm thick on a tool’s surface. See coated tools; PVD, physical vapor deposition.
- computer numerical control ( CNC)
computer numerical control ( CNC)
Microprocessor-based controller dedicated to a machine tool that permits the creation or modification of parts. Programmed numerical control activates the machine’s servos and spindle drives and controls the various machining operations. See DNC, direct numerical control; NC, numerical control.
- cubic boron nitride ( CBN)
cubic boron nitride ( CBN)
Crystal manufactured from boron nitride under high pressure and temperature. Used to cut hard-to-machine ferrous and nickel-base materials up to 70 HRC. Second hardest material after diamond. See superabrasive tools.
- cubic boron nitride ( CBN)2
cubic boron nitride ( CBN)
Crystal manufactured from boron nitride under high pressure and temperature. Used to cut hard-to-machine ferrous and nickel-base materials up to 70 HRC. Second hardest material after diamond. See superabrasive tools.
- electrical-discharge grinding ( EDG)
electrical-discharge grinding ( EDG)
Process similar to conventional electrical-discharge machining except a grinding-wheel type of electrode is used. See EDM, electrical-discharge machining.
- electrical-discharge machining ( EDM)
electrical-discharge machining ( EDM)
Process that vaporizes conductive materials by controlled application of pulsed electrical current that flows between a workpiece and electrode (tool) in a dielectric fluid. Permits machining shapes to tight accuracies without the internal stresses conventional machining often generates. Useful in diemaking.
- endmill
endmill
Milling cutter held by its shank that cuts on its periphery and, if so configured, on its free end. Takes a variety of shapes (single- and double-end, roughing, ballnose and cup-end) and sizes (stub, medium, long and extra-long). Also comes with differing numbers of flutes.
- feed
feed
Rate of change of position of the tool as a whole, relative to the workpiece while cutting.
- grinding
grinding
Machining operation in which material is removed from the workpiece by a powered abrasive wheel, stone, belt, paste, sheet, compound, slurry, etc. Takes various forms: surface grinding (creates flat and/or squared surfaces); cylindrical grinding (for external cylindrical and tapered shapes, fillets, undercuts, etc.); centerless grinding; chamfering; thread and form grinding; tool and cutter grinding; offhand grinding; lapping and polishing (grinding with extremely fine grits to create ultrasmooth surfaces); honing; and disc grinding.
- metrology
metrology
Science of measurement; the principles on which precision machining, quality control and inspection are based. See precision machining, measurement.
- micron
micron
Measure of length that is equal to one-millionth of a meter.
- polycrystalline cubic boron nitride ( PCBN)
polycrystalline cubic boron nitride ( PCBN)
Cutting tool material consisting of polycrystalline cubic boron nitride with a metallic or ceramic binder. PCBN is available either as a tip brazed to a carbide insert carrier or as a solid insert. Primarily used for cutting hardened ferrous alloys.
- polycrystalline diamond ( PCD)
polycrystalline diamond ( PCD)
Cutting tool material consisting of natural or synthetic diamond crystals bonded together under high pressure at elevated temperatures. PCD is available as a tip brazed to a carbide insert carrier. Used for machining nonferrous alloys and nonmetallic materials at high cutting speeds.
- polycrystalline diamond ( PCD)2
polycrystalline diamond ( PCD)
Cutting tool material consisting of natural or synthetic diamond crystals bonded together under high pressure at elevated temperatures. PCD is available as a tip brazed to a carbide insert carrier. Used for machining nonferrous alloys and nonmetallic materials at high cutting speeds.
- relief
relief
Space provided behind the cutting edges to prevent rubbing. Sometimes called primary relief. Secondary relief provides additional space behind primary relief. Relief on end teeth is axial relief; relief on side teeth is peripheral relief.
