1 Introduction <br> <br> high hardness of diamond tools and other excellent properties make it very suitable silicon alloy processing, non-ferrous metal materials aluminum alloy, copper alloy and fiber-reinforced composite material, a phenol resin, graphite, and other non-metallic materials. Natural diamond materials are limited in their application due to their small size, high price, and difficulty in processing. Although the artificial polycrystalline diamond (PCD) tool plays an important role in the semi-finishing and finishing fields, its excellent performance is difficult to fully exert due to the single shape of the blade, the no chip breaker, and the limitations of geometric parameters. The diamond thick film tool is a new type of tool made by welding a deposited thick diamond film on a cemented carbide blade, which has excellent processing performance and high performance-price ratio. China's research, development and application of diamond thick film end mills are still in their infancy. In this paper, the microstructure, design and preparation of diamond thick film end mill and its application in superfinishing are studied.
2 diamond thick <br> <br> microstructure analysis to study the workability of diamond tools thick, with a scanning electron microscope JSOM35C microstructure domestic and imported diamond thick PCD compact comparison test were analyzed, It can be seen from the microscopic images of the two materials that the microstructure of the PCD composite sheet is a granular polycrystalline structure with many voids and many needle-like graphite bodies; due to the addition of a small amount of bonding during the preparation of high temperature and high pressure. Agent, so its hardness is affected (HK5000 ~ 8000), lower than the hardness of natural diamond, but its impact strength is higher; the cutting edge of the tool made of PCD composite sheet presents many uneven micro-aliasing, so it is suitable for Semi-finishing and finishing, but not suitable for ultra-finishing that requires mirror-level surface accuracy. It can be seen from Fig. 2 that the microstructure of the diamond thick film is complete and single, the void is small and fine, similar to the single crystal diamond; since the material structure is completely composed of diamond, no binder inclusion, it has a higher hardness (HK8300), close to The average hardness value of natural diamond; if a proper sharpening process is used, the diamond thick film cutter can obtain a non-serrated linear blade, which is very suitable for super finishing of mirror surface precision.
3 an end mill <br> <br> design and preparation of comparative cutting tests were thick and diamond PCD compact prepared end mill having the same shape and geometric parameters. The preferred end mill design parameters are: diameter Ø125mm, the number of teeth is 6 teeth, the cutting depth is 3°~8°, the radial rake angle is 0°～-5°, the main declination is 75°; the cemented carbide substrate The YG3X square blade is used, and the cutter body adopts the indexable front pressure type, and the thickness, aperture and connection size of the cutter body are designed according to national standards.
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