finer points · from intertech 2017 technical ... (e.g., grinding wheels, dressing tools, drill...

FinerPointsTHIS ISSUE

A Finer Point of View

Editorial

Calendar of Events

News & Notes

New Products

“BEST IN CLASS”Education Course –SuperabrasivesMaterials, Principles &Applications

Paper Excerpts fromINTERTECH 2017

IDA MemberCompanies

MembershipApplication

Ad Insertion Order

INTERTECH 2019 in New Orleans

THE LONGESTRUNNING

MAGAZINEDEDICATED

SOLELY TO THETECHNOLOGY AND

APPLICATION OFSUPERABRASIVES

Summer 2017 $9.00 USD

SUPERABRASIVE INDUSTRY REVIEWFeaturing INTERTECH 2017 Conference Excerpts and Review

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d e p a r t m e n t s

4 A Finer Point of View

6 Editorial

9 News & Notes

10 New Products

25 MembershipApplication

26 Ad Insertion Order

COVER PHOTOPhoto of High Pressure High

Temperature Cube Press used tomanufacture polycrystalline diamond,courtesy of US Synthetic Corporation

from INTERTECH 2017 technicalpresentation.

American Superabrasives Corp. ............................................................................................ 29

Apogee Precision Parts ............................................................................................................. 7

Bogimac NV-SA ......................................................................................................................... 6

CR Gems Superabrasives Co., Ltd. ...................................................................................... 19

Crystallume Engineered Diamond Products ........................................................................ 8

Element Six US Corporation ............................................................................................ OBC

The Grinding Doc ................................................................................................................ 24

ILJIN USA, Inc. ...................................................................................................................... 17

Lands Superabrasives .............................................................................................................. 5

Niabraze, LLC .......................................................................................................................... 10

Standard Die & Fabricating Inc. ........................................................................................ IBC

Trigon Technologies................................................................................................................ 28

Vollstädt-Diamant ................................................................................................................... 29

Worldwide Superabrasives LLC ........................................................................................... IFC

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8 Calendar of Events

11 “BEST IN CLASS” Education Course –Superabrasives Materials, Principles& Applications

12 Paper Excerpts fromINTERTECH 2017

16 IDA Member Companies

27 INTERTECH 2019 in New Orleans

FINER POINTS is the longest running publication devoted exclusively to the understanding, selection andapplication of diamond, cubic boron nitride and related materials. It is edited for recipients who are involved insome way with these “superabrasives”, either as providers of the materials, producers of products containing thematerials or users of these products (e.g., grinding wheels, dressing tools, drill bits, saw blades, sawing wires,cutting tools, polishing compounds, CVD film products, etc.).

FinerPoints

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Featuring INTERTECH 2017 Conference Excerpts and Review FINER POINTS

A Finer Point of View... Industrial DiamondAssociation ofAmerica, Inc.

PRESIDENTEd FrancisCrystallume Engineered Diamond

VICE PRESIDENTShane HollenbaughYG-1 USA

SECRETARY/TREASURERKevin StilesRadiac Abrasives A Tyrolit Company

PAST PRESIDENTBen WilliamsFACT USA

BOARD OF DIRECTORS (term)Marc Modersitzki (17-19)US Synthetic CorporationMichael Lew (17-19)MWI Eloquence CorporationJim Long (17-19)Greenlee Diamond Tool CompanyJulie Griffin (16-18)Precision eForming

Eric P. Bieberich (16-18)Fort Wayne Wire Die

Aaron Nolan (17-19)Worldwide Superabrasives, Solids Division

Open Seat– To Be Appointed (16-18)

EXECUTIVE DIRECTORMr. Terry M. KaneIndustrial Diamond Associationof America, Inc.P.O. Box 29460 • Columbus, Ohio 43229Phone: 614-797-2265FAX: 614-797-2264Email: [email protected]

BUSINESS MANAGERKathryn A. KaneIndustrial Diamond Associationof America, Inc.P.O. Box 29460 • Columbus, Ohio 43229Phone: 614-797-2265FAX: 614-797-2264Email: [email protected]

Website: www.superabrasives.org

FINER POINTS is the official publication of theIndustrial Diamond Association of America, Inc. and ispublished fours times a year. Contributions arewelcomed but the Editor reserves the right to accept orreject any material deemed inappropriate forpublication. All by-lined articles published in thismagazine represent solely the individual opinions of thewriters and not necessarily those of the IndustrialDiamond Association. Executive and Editorial Offices:Finer Points, P.O. Box 29460, Columbus, Ohio 43229,(614) 797-2265. Editor and Advertising, Terry Kane.Advertising rates and deadlines available upon request.Copyright Industrial Diamond Association of America.Material in FINER POINTS may not be reproduced inany form without express written consent.

ISSN: 1090-0896

4 FINER POINTS Featuring INTERTECH 2017 Conference Excerpts and Review

Thank you to the Members and theBoard of Directors for theopportunity to serve as thePresident of Industrial DiamondAssociation of America for thecoming year. I would like to thankmy predecessor Ben Williams forthe excellent job he has doneleading us in the past year to asuccessful INTERTECH 2017 andEducation Course in November of2016. I look forward to building onthis momentum to keep ourorganization moving forward in thecoming twelve months.

Our organization is a communityconnected by relationships andsuperabrasives. With INTERTECHand the annual meeting we providea place for members to networkwith other ED FRANCIS membersfor their personal and businessgrowth and to those of you Ihaven’t met I look forward tomeeting you during the comingtwelve months.

We need to focus on bringing thebest value we can to our members,and continue to educate the newand old generation in the use andapplication of superabrasives. TheIndustrial Diamond Associationshould be the Go To location foranyone needing to learn moreabout superabrasives and/or ourmember companies.

Our members look to ourorganization to provide up to dateeconomic and technicalinformation in these changingtimes. Finer Points gives us thetraditional print method of gettinginformation out to our membersand superabrasives community. TheIDA web sites provide a resourcethat can be accessed any timeanywhere for people in search ofsuperabrasive information. Themonthly IDA eMail Newslettergives members timely informationabout our industry and the issuesthat affect it. There may be otheroptions we have not explored yetthat may also become ways toexpand the benefits of IDAmembership.

I hope with the help and input ofthe members, we can continue tomake this a world-classorganization that the members areproud to say that they belong.

In closing it is easy to connect thedots looking back but as we are inthe midst of finding our wayforward in challenging times I am

reminded of the commencementaddress given to the 2005graduating class at Stanford bySteve Jobs (http://news.stanford.edu/2005/06/14/jobs-061505/ )about how the events in his lifeseemed disconnected but lookingback it all made sense.

A small excerpt from Steve’s talk toget you interested; “I didn’t see itthen, but it turned out that gettingfired from Apple was the best thingthat could have ever happened tome. The heaviness of being successfulwas replaced by the lightness ofbeing a beginner again, less sureabout everything. It freed me toenter one of the most creative periodsof my life. During the next fiveyears, I started a company namedNeXT, another company namedPixar, and fell in love with anamazing woman who would becomemy wife. Pixar went on to create theworld’s first computer animatedfeature film, Toy Story, and is nowthe most successful animation studioin the world. In a remarkable turnof events, Apple bought NeXT, Ireturned to Apple, and thetechnology we developed at NeXT isat the heart of Apple’s currentrenaissance. And Laurene and I havea wonderful family together.”

This is why it is so important tokeep moving forward and we willfind that it all connects.

Best regards,

Ed Francis, PresidentIndustrial Diamond Association of America

PRESIDENTEd Francis


INTERTECH, THE INDUSTRYBENCHMARK OF TECHNICALEXCELLENCEThe Industrial Diamond Association of America justfinished hosting another INTERTECH. It is hard tobelieve that this conference has withstood the test oftime to remain the premier conference on industrialdiamond, cubic boron nitride and their applications.It was my pleasure to serve on the first organizingcommittee for INTERTECH 2000 and since that timeI have been honored to serve as the Chairman for

every INTERTECH. We have seen innovations and new technology in mostindustries, from diamond prosthetics and nanodiamond cancer killing drugs inMedical to composite drilling and superalloy manufacturing in Aerospace. Yes,in Optics, Automotive or Construction INTERTECH has heralded so manyremarkable applications and new products it is impossible to list them all.Sometimes we forget that superabrasives keep evolving and new generationsprovide even more remarkable results. CVD Diamond has created newpossibilities and coated mesh abrasives or polycrystalline innovations keep ourindustry new and exciting! INTERTECH 2017 was held this year in SanFrancisco and our attendees had the opportunity to hear excellent Keynoteaddresses from noteworthy and distinguished speakers representing leadingindustry businesses and innovative diamond research. Eminent diamondindustry scientist Dr. James Butler retired from the Naval Research Laboratoryin 2010 after 35 years of research. His current research interests lie primarilywith understanding and exploiting the growth, characterization, properties, andapplications of chemical vapor deposited (CVD) diamond materials. Dr. Butlerspoke on Advances in Single Crystal Diamond: Enabling Active DiamondElectronics. Shane Collins also was a Keynote and is currently the Director ofAdditive Manufacturing Programs at CalRAM. Shane holds the position ofChairman of the American Society for Testing and Materials (ASTM) F42materials and process subcommittee on additive manufacturing and spoke onthe international development and publication of technical standards for awide range of materials, products, systems, and services.Another Keynote address was given by Paul Zimnisky ofDiamond Analytics in the New York City, he has worked inthe capital markets industry for over 10 years where he hasheld leading roles as a metals and mining analyst, arbitragetrader, exchange-traded fund developer, and consultant. Mr.Zimnisky spoke on the State of the Natural DiamondIndustry and covered the global supply and demand fornatural diamond. Attendees also had an outstanding arrayof technical papers from international presentersrepresenting multiple disciplines and a number of tabletopdisplays featuring various companiesand their products. Judging from theevaluations submitted, thisINTERTECH may have been the bestyet in terms of technical papers,amenities, events and interest.Everyone seems very excited aboutparticipating in and/or attendingINTERTECH 2019 in New Orleans!

TERRY KANE, Editor


AUGUST 6-9, 2017AEROSPACE CONFERENCE 2017Fairmont Le Château Frontenac, Québec CityQuebec, Canada

http://aerospace2017.com

AUGUST 29-31, 20172017 SC Aerospace Conference & ExpoColumbia Metropolitan

Convention Center • Columbia, SC •http://southcarolinaaerospaceconference.com

SEPTEMBER 7-8, 2017CSDA Board & Committee Meeting

The Westin Phoenix Downtown,Phoenix, AZ • www.csda.org

SEPTEMBER 12-14, 2017

Los Angeles Convention Center Los Angeles, CA • www.westeconline.com

SEPTEMBER 13-15, 2017North AmericanInternational Powertrain Conference

Chicago, Illinois, USAFairmont Millennium Park Hotelhttp://www.sae.org/events/naipc/

SEPTEMBER 19-21, 2017Wire Southeast Asia 2017Bangkok Trade & Exhibition Centre • Bangkok, Thailandhttp://www.wirenet.org/viewcalendar/viewevent/111wiresoutheast-asia-2017

SEPTEMBER 25-28, 2017The International CentreMississauga (Toronto), ON,Canada • http://cmts.ca/

SEPTEMBER 26-28, 2017AeroTech Congress &Exhibition Fort Worth, Texas, USA

Ft. Worth Convention Centerhttp://www.sae.org/events/atc/

OCTOBER 3-5, 2017Connecticut Convention Center

Hall A • Hartford Marriott Downtownhttp://www.metalengineeringexpo.org/

OCTOBER 9-14, 2017CSDA Training Down

Oct. 9-10 Slab Sawing & Core DrillingOct. 11-12 Wall Sawing & Hand SawingOct. 13-14 Wire Sawing 101, ICS Blount,Inc., Portland, OR • www.csda.org

OCTOBER 10-12, 2017Additive Manufacturing Conference 2017

Knoxville Convention Center, Knoxville, TNhttp://www.additiveconference.com/

OCTOBER 24-26, 2017TD Convention CenterGreenville, SC

www.southteconline.com

NOVEMBER 6-9, 2017McCormick PlaceChicago, IL

http://www.fabtechexpo.com/

FALL 2017Industrial DiamondAssociation of AmericaSuperabrasive Materials,Principles & ApplicationsEducation Course Watch for details at:

www.superabrasiveseducation.com

MAY 29, 30 & 31, 2019Hyatt Regency New Orleans

New Orleans, Lousiana USAwww.intertechconference.com

To have your event or conference listed,please send information to: Finer Points

Event Calendar • P.O. Box 29460,Columbus OH 43229 • Fax 614-797-2264

or email: [email protected]

9Featuring INTERTECH 2017 Conference Excerpts and Review FINER POINTS

NEW BOARD OF DIRECTORS FORINDUSTRIAL DIAMOND ASSOCIATIONOF AMERICA (IDA) ANNOUNCED ATINTERTECH 2017At the recent INTERTECH the new Board of Directors were inducted. Welcome to new officers PRESIDENT- Ed Francis of Crystallume Engineered Diamond, VICE PRESIDENT - ShaneHollenbaugh of YG-1 USA, SECRETARY/TREASURER - Kevin Stiles of RadiacAbrasives A Tyrolit Company and PAST PRESIDENT - Ben Williams of FACT USA.Incoming DIRECTORS are Marc Modersitzki of US Synthetic Corporation, MichaelLew of MWI Eloquence Corporation, Jim Long of Greenlee Diamond ToolCompany, Julie Griffin of Precision eForming, Eric Bieberich of Fort Wayne Wire Dieand Aaron Nolan of Worldwide Superabrasives Solids Division. The IDAManagement team of EXECUTIVE DIRECTOR Terry Kane and BUSINESSMANAGER Kathy Kane were also recognized.

BOEING’S LATEST PASSENGER JETENTERS INTO SERVICE WITH METALADDITIVELY MANUFACTURED ENGINECOMPONENTSGE has reported the first regular flight of theBoeing 737 MAX 8, an aircraft which is poweredby two CFM International LEAP-1B engines. The LEAP engines are the first to be built with additively manufacturedfuel nozzles. According to GE Reports, fuel nozzles made thisway can be manufactured in a single, complex piece instead ofrequiring assembly. This makes them lighter and more durable,helping to improve the aircraft’s fuel burn. LEAP engines weredeveloped by engineers with CFM International, a joint venturebetween GE Aviation and France’s Safran Aircraft Engines, and have been inoperation since 2008. Altogether, GE states that LEAP-1B engines are providing15% lower fuel consumption compared with the CFM56-7B engines operating ontoday’s global 737 fleet. With a running tally of 12,230 orders valued around $170billion (US list price), the LEAP is the bestselling engine in GE Aviation’s history.

GLOBAL STEEL PRODUCTION CONTINUED STEADY RISEWorld crude steel production for the 67countries reporting to the World SteelAssociation was 142.1 million tonnes (Mt) inApril 2017, a 5.0% increase compared to April2016. China’s crude steel production for April2017 was 72.8 Mt, an increase of 4.9%compared to April 2016. Japan produced 8.8Mt of crude steel in April 2017, an increase of3.0% compared to April 2016. South Korea’scrude steel production for April 2017 was 5.5

Mt, a decrease of - 2.9% compared to April 2016. In the EU, Germany produced3.9 Mt of crude steel in April 2017, an increase of 8.1% compared to April 2016.Italy produced 2.0 Mt of crude steel, down by -6.0% on April 2016. Franceproduced 1.3 Mt of crude steel, up by 30.8% compared to April 2016. Spainproduced 1.2 Mt of crude steel, down by -2.8% on April 2016. Turkey’s crude steelproduction for April 2017 was 3.0 Mt, up by 6.5% on April 2016. The US produced6.7 Mt of crude steel in April 2017, an increase of 1.8% compared to April 2016.Brazil’s crude steel production for April 2017 was 2.9 Mt, up by 25.9% on April2016. The crude steel capacity utilization ratio of the 67 countries in April 2017 was73.6%. This is 2.5 percentage points higher than April 2016. Compared to March2017, it is 1.7 percentage points higher.

THE RESHORING INITIATIVE AND PMA LAUNCHFIRST NATIONAL RESHORING AWARD The Reshoring Initiative, in conjunction with the PrecisionMetalforming Association (PMA), invites companies that havesuccessfully reshored parts or tooling made primarily by metal forming, fabricating or machining to apply for the firstNational Reshoring Award. There will be one award for buyers andone award for suppliers. To be eligible for the award, the reshoringwork must have occurred between January 1, 2012, and August 1, 2017, and thework must have come back from outside North America to North America.Applications must be submitted by August 1, 2017. To view award details andenter to win, visit www.pma.org/sourcingsolutions/reshoring.asp.

AN

D

NEWS&notes Lt to Rt Executive Director Terry Kane, Past

President Ben Williams and President Ed Francis


ELEMENT SIX INTRODUCES THE FIRSTELECTRICALLY CONDUCTIVE CVD DIAMONDHEAT SPREADER, DIAFILM™ ETC700, FOR HIGHFREQUENCY & ADVANCED ELECTRONIC DEVICESDiafilm™ ETC700 delivers exceptional heat dissipation combined with minimalresistive and RF losses, enabling smaller and more reliable high power densitydevices without impeding electrical performance. Element Six, a world leader insynthetic diamond supermaterials and member of The De Beers Group ofCompanies, announced today the development of a new thermal grade of syntheticdiamond grown by chemical vapor deposition (CVD), Diafilm™ ETC700. Thematerial is both thermally and electrically conductive and is uniquely suited toeffectively manage heat in high frequency, high power density devices. With athermal conductivity up to 700 W/mK, Diafilm ETC700 CVD diamond heat spreadersare three times more effective in spreading heat than alternative ceramic solutions.This electrically conductive all-diamond solution does not require the metal coatingstypical of other heat management materials, resulting in reduced frequencydependent conductive losses. Diafilm ETC700 offers better electrical deviceoperation, lower operating temperatures and improved reliability and longerlifespans of high frequency active semiconductors. If interested in learning moreabout Element Six’s advanced thermal management materials including the newlylaunched Diafilm ETC700, please visit www.e6.com/thermal.

LARSON ELECTRONICS ANNOUNCES THE RELEASEOF A NEW EXPLOSION PROOF HIGH BAY LEDLIGHT FIXTURELarson Electronics, a leading industrial lighting company, announcedthe release of a new explosion proof high bay LED light fixture (EPL-HB-150LED-RT-NSF) to be added to its expanding catalog ofproducts this week. This hazardous location light is approved for usewithin environments where flammable or combustible gases, vapors,

dusts, and fibers exist or stand the potential to exist and is ideal for a variety ofapplications for safe lighting. This Class 1 LED light fixture has no exposed glassand provides 17,500 lumens of light while only drawing 150 watts.

Announcements&PRODUCTS

LACH DIAMOND PRESENTS NEW PCDTWIST DRILLS TYPE PSSuper fast drills are ideal for machiningcomposites, green carbide, ceramics andgraphite. LACH DIAMOND’s newly developed PCDtwist drill type PS saves up to 75% of time by reducing three previously necessarysteps to one process. The new PCD twist drill completes piloting, drilling andreaming all in one “shot”. LACH DIAMOND looks back on a long tradition ofdeveloping and manufacturing PCD drills for the machining of composites – CFRP- GRP – especially for use in aircraft and automotive lightweight construction.LACH DIAMOND PCD twist drills with a point angle of 70° to 180° are availablewith either double cone or step drill geometry and a double margin for drillingqualities up to h6. The drills are available from ø 2.5 to 12 mm standard size.

SCHUNK EXPANDS MICRO-MACHINING PRODUCTSTRIBOS polygonal clamping technology has been setting standards inhighprecision micro machining for many years. Numerous companies in medicaland dental technology, watchmaking, and jewelry, as well as mold making andoptical engineering have put their confidence in SCHUNK’s patented toolholdingsystem. Due to the high demand, SCHUNK has now further expanded the line ofprecision toolholders. The SCHUNK TRIBOS-Mini, designed for micro applications,

is now available for high-speed spindle interface HSK-E 20.Compared to conventional steep-angle taper interfaces; theHSK-E 20 ensures exact contact of the toolholder, whichallows outstanding change and positioning accuracy. Inaddition, the close tolerances of the tapered seat result inmaximum precision and superior running smoothness at highspeeds. SCHUNK has made improvements in other interfacesas well: the TRIBOS-Mini and TRIBOS-RM series with theinterfaces HSK-E 25, and HSK-E 32, starting with clampingdiameters of 0.5 mm are now optionally available in fine-balanced versions with a balancing grade of G 0.3 at 60,000rpm. TRIBOS can also be used for applications with very highrequirements for dimensional stability and surface quality.


THE INDUSTRIAL DIAMOND ASSOCIATION OF AMERICA (IDA)Presents

“BEST IN CLASS” Education CourseSuperabrasive Materials, Principles & Applications

COURSE PLANNED FOR FALL 2017 –DATES AND LOCATION BEING FINALIZED

VISIT: WWW.SUPERABRASIVESEDUCATION.COM FOR COMPLETE DETAILS

NEW SUPERABRASIVE EDUCATION COURSETWO FULL DAYS

ONE FULL DAY OF GRINDING • ONE FULL DAY MACHININGFULL TWO DAY EDUCATION COURSE FEE, STILL ONLY $525 USD

Discounts for early payment and to IDA Members!Classroom technical and instructional sessions will be highlighted by

laboratory demonstrations and class interaction featuring: Truing & Dressing Applications Thermal Testing & Evaluations Grinding Demonstrations and Surface Analysis And More! Machining of Exotic Materials

OBJECTIVE"Superabrasive Materials Principles and Applications" is sponsored by the IDA and designed specifically toeducate on the use of industrial diamond, cubic boron nitride (cBN) materials classified as superabrasives.It is Non-commercial, unbiased and representative of accepted principles and practices. Content willinclude a wide range of products and applications for the automotive, aerospace, medical, electronics,optics and other industries using superabrasives. The attendee will be educated in the primary areas ofgrinding and machining with peripheral explanation for other uses, such as non-abrasive applications.

WHO SHOULD ATTEND?This Course will educate End Users processing materials made from difficult to machine and grindmaterials such as hardened steel, stainless steel, superalloys, titanium, high silicon aluminum,composites, ceramics, bi-metals, metal matrix composites, cermets, glass, and more! It will alsoeducate Machine Tool Builders, Abrasive suppliers, Raw Material Suppliers, Machine Operators, WheelMakers, Tool Makers, Research Scientists, Academia, Engineers, Sales Personnel or anyone wishing tolearn more about superabrasives.

INSTRUCTORS ARE INDUSTRY EXPERTS WITH MANYYEARS COMBINED EXPERIENCE!

Each one has with “real world” knowledge of superabrasives, applications and characteristics. They havealready established manufacturing operations in aerospace, automotive and literally every other productionoperation around the world. Now, you can learn what superabrasives are, where they are used and thecharacteristics and properties that affect their performance in manufacturing operations. Do you want tounderstand wear mechanisms in machining and grinding? What is friability? What is a rake angle? Whataffects chip formation? What crystal is used in a given application? How does burn and thermal damageaffect structural integrity of a part? What is residual stress in metal components such as turbine engine fanblades? Why true & dress a wheel? What are the different coolant types and delivery systems? What isedge prep on a cutting tool and why is it performed? What is the Modulus of Resistance and what abrasiveperforms best on a particular workpiece material and why? If you currently are using conventionalabrasives you will learn the advantages of superabrasives and how they can be applied to increaseproductivity, reduce scrap and improve the cost effectiveness in manufacturing operations.


Paper Excerpts of INTERTECH 2017 on the following pages.

ABRASIVE WEAR PROPERTIES OFTHERMALLY STABLE DIAMONDCOMPOSITE MATERIALSJ.N. BOLAND, X.S. LI AND C. HARBERSCSIRO Energy, 1 Technology Court, Pullenvale, Queensland AUSTRALIA 4069

IntroductionThere are many parameters that influence the wear properties ofdiamond composite materials. Such parameters as manufacturingprocess, diamond grain size distribution as well as the addition ofsecondary phases that nominally act as bonding agents (Field, 1992and references therein; Wilks, 1991 & 1992). The present study isfocussed on characterising the specific class of diamond compositesreferred to as thermally stable diamond composite (TSDC) in whichthe binder phase is usually silicon carbide (SiC) and themanufacturing process involves the reactive sintering of the diamondphase with molten silicon metal via a carbide formation reaction thatfacilitates the bonding of the diamond grains (Boland and Li, 2010).The exceptional wear resistance of TSDC as an abrasive wear resistantmaterial has been shown in an earlier study by Li and Boland (2005).Further, with the development of TSDC, tools with these cuttingelements are able to operate up to 1300oC which is much greater thanthe usual limitation of ~800oC of PCD (polycrystalline diamond)class of diamond composites (Boland et al, 2014).

Characterisation of Materials andExperimental MethodsThe materials used in this study constitute an integral part of a muchbroader research program aimed at optimising the wear resistance andmechanical properties of thermally stable diamond compositematerials for industrial applications. All samples were reactivelysintered in the diamond stability field (1550oC, 5.5 GPa) by acommercial manufacturing company. The major sintering additive wasmetallic Si which, at these high pressure, high temperature (HPHT)conditions, melted and infused through the interstices in the diamondpowder. The specifications of the specific subset of samples used inthis study are given in Table 1 in which the composition of thesamples is listed as the weight percentage of the starting granularphases (silicon and diamond).

Material CharacterisationAll samples – both the starting powder mixes and the reactivelysintered products - were examined using (a) a Malvern Mastersizer

Complete Paper Available on INTERTECH 2017 Proceedings Download LinkOrder at www.intertechconference.com

Characteristic ofSynthetic Diamondfor Dressing ToolsYUTAKA KOBAYASHI, TAKERU NAKASHIMA, TADASHI YAMAGUCHISumitomo Electric Hardmetal Corp.1-1-1 Koyakita, Itami, Hyogo, 664-0016 Japan

As alternative material for a natural diamond, synthetic diamondis used for dressing tools. For excellent performance, it is necessaryto understand the orientation dependence on wear resistance andto select proper orientation when making and using a dresser. Inregard to synthetic diamond for dressing tools, its characteristics

and using method are described in detail.

1. Synthesis Methods of Single Crystal Large DiamondAs it is well known, there are various methods for diamondsynthesis such as temperature gradient (difference) method orsolubility difference method under static high pressure,dynamic high pressure (shock wave) method, and chemicalvapor deposition method. Among these methods, using thetemperature gradient method under static high pressure isthought to be most effective to grow large, good qualitydiamond crystals of several millimeters. In this method, acarbon source is placed at the hotter part above the solvent(made from ferrous metals, such as Fe, Ni and Co) and the seedcrystal is positioned at the cooler part under the solvent in thehigh-pressure reaction cell. The driving force for crystallizationarises from the difference in the solubility of diamond in thesolvent that is caused by the temperature gradient in thereaction cell (Fig. 1).

2. Orientation Dependence on Wear Resistance2-1 ExperimentalRectangular solids (0.8x0.8x3.0 mm3) with end face of (100),(110), (211) and (111) plane were prepared using syntheticdiamond. Each solid was ground with metal-bond diamondwheel (Allied Diamond #800) in the wheel speed of 50m/sec.under dry condition for 2 minutes. Pressing load was 0.5kgf. Toprevent initial chippings or no uniform wear, some pre-dressingon the testing surface was put to make it smooth. Wear lengthwas measured after grinding for each plane changing dressingdirection on the plane. Hereinafter “(110) <110>” denotes <110>direction on (110) plane for convenience sake.

2-2 Result and DiscussionComparisons of wear volume in various directions on eachplane were shown in Fig. 2. The results were almost consistentwith the previous works. We found that wear resistance on (211)<110> and (211) <110> are then highest next to (111) plane.

13

Complete Paper Available on INTERTECH 2017 Proceedings DownloadLink • Order at www.intertechconference.com

Featuring INTERTECH 2017 Conference Excerpts and Review FINER POINTS

STACK DRILLINGwith Diamond ToolMaterialsSTEPHEN KELLYRegional Technical Manager - the US, Canada & Latin AmericaBE (Hons.) Mechanical Engineer, MSc Management, CEng

The aerospace industry has pioneered the use of carbon fibre reinforcedpolymers (CFRP) for numerous years and in many shapes, sizes and types.For applications where CFRP alone might fail, further materials such asAluminium and/or Titanium are combined to make a multi-material stack. In asafety-conscious industry, mechanical fastening is the method of choice forjoining components. This results in the requirement to produce manythousands of holes per aircraft. Hole production to tight tolerances, typicallyH8, and high economic efficiency requirements, mean CFRP alone is asignificant challenge. When adding dissimilar materials in a stack format,hole production becomes highly problematic.

Diamond tooling has proven to be highly successful in drilling CFRP due toits extreme properties such as high hardness, abrasion resistance andthermal stability. There has previously been a gap between the ability toproduce the complex cutting geometries required for extreme applicationsand the shapes of formats available in solid diamond materials. Attempts tobridge this gap using Diamond-like Carbon Coating (DLC) and ChemicalVapour Deposition (CVD) diamond coating of Tungsten Carbide (WC) toolgeometries have been partially-successful. However, the unpredictablechipping performance of coatings leads to variable performance and toollife. Combined with the high economic cost of resharpening, this makescoatings less desirable as a tool material than solid diamond in the form ofPCD (Polycrystalline Diamond). The advancements in recent years of 3DPCD formats such as Element Six’s Aero-Dianamics™ range, coupled withstate of the art tool processing methods such as Electro-DischargeMachining (EDG) and laser processing, has brought PCD to the forefront ofcutting tool technology for extreme applications.

So why is a multi-material stack so difficult to machine, even with such anextreme tool material like diamond? The three most common materialsutilised in stacks are CFRP, Titanium (Ti) and Aluminium (Al), withconfigurations such as CFRP/Ti, CFRP/Al or Ti/CFRP/Al. CFRP alone is verydifficult to machine due to its anistropic and non-homogeneous structurecombined with highly abrasive reinforcing constituents. Added to this, theresin matrix material typically has a very low temperature resistance. Oncethe resin’s critical temperature is reached, permanent damage occurs whichincreases quality issues such as delamination, fibre breakout and uncutfibres. Controlling the process parameters such as cutting speed and feedrate are critical in order to control the temperature generation during cutting.While maintaining a sharp cutting edge enables more effective cutting ofeach fibre by brittle fracture. In comparison, Aluminium presents a mucheasier material to machine, by ductile shearing and little abrasive wearresults. However, issues such as chip control, built-up-edge and exit burrformation can be difficult issues to control when the tool begins to wear.Contrasting to Aluminium, Titanium is typically extremely difficult to machinedue to its low thermal conductivity and high chemical affinity. These causeexcessive adhesion of Ti material to the cutting edge which causes aplucking phenomenon to occur, and eventually premature tool failure.Titanium’s low thermal conductivity means all the heat generated at the pointof cutting is transferred into the tool. And of course its high strength, retainedeven at high temperatures, causes high forces during cutting.


Complete Paper Available on INTERTECH 2017 Proceedings Download LinkOrder at www.intertechconference.com


INTRODUCTIONPCBN(Poly Cubic Boron Nitride is made of cbn and many different bindermaterials by sintering under HPHT(High Pressure High Temperature)condition and widely used as cutting tool material when machining castiron, hardened steelor hard to machine alloys such as Ni-based superalloy.This paper introduces a new cbn grade developed by a novel method ofpowder mixing and microstructure design.

PCBNLow content PCBN is generally used for the machining of hardened steelparts. When manufacturing PCBN, strength, shape and the size of cbnpowder are important. Also suitable choice of binder materials andmicrostructure design are key factors. This study is about a new PCBNgrade, specifically developed targeting interrupted machining of hardenedsteel parts. The PCBN grade has good physical properties of hardness,

impact and chipping resistance. And electrically conductivesecondary composites are distributed along the grainboundary leading to smooth WEDM cutting. Fig. 1 shows theSEM image of a) conventional low content PCBN, b) new lowcontent PCBN. It is clear that the microstructure of the newPCBN is highly uniform. Fig. 2 is the TEM image of secondarycomposites such as TiB2, TiN and AlN distributed along thecbn grain boundary.

PERFORMANCE TESTMachining tests of hardened steel were carried out with thenew PCBN and competing PCBN grades in the market. Thework material was SCM440H (42CrMo4 / ASTM4140).Performance test 1 is the interrupted turning of hardened

ABSTRACTA lot of automotive parts aremade with hardened steelhaving hardness of 40 ~ 60HRc. When machininghardened steel, PCBN cuttingtool offers many benefits suchas increased productivity, highefficiency and environmentallyfriendly operation. In thispaper, newly developed lowcontent PCBN grade,specifically engineered formoderate to heavy interruptedhard turning of hardened steel,is introduced.

Development of Low Content PCBN forInterrupted Machining of Hardened Steel

Y. J. SHIN*, J. S. WOO*, H. W. LEE**, JEREMY PETERSON***

*Research Engineer / ILJIN Diamond Co., Ltd.** Senior Research Manager / ILJIN Diamond Co. Ltd.***Technical Sales Manager / ILJIN USA, Inc.

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3M Abrasive Systems Divisionwww.mmm.com

ABC & Warren/Amplex Superabrasiveswww.saint-gobain.com

Abrasive Technologywww.abrasive-tech.com

Abrasivos Austromex, S.A. DE C.V.www.austromex.com.mx

Action Superabrasive Products, Incwww.actionsuper.com

Advanced Abrasives Corporationwww.advancedabrasives.com

American Superabrasives Corp.www.diamonds-abrasive.com

Anco Industrial Diamond Corp.www.ancodiamond.com

Apogee Precision Partswww.natchain.com

Asahi Diamond Americawww.asahidiamond.com

Bogimac NV-SAwww.bogimac.com

Bruce Diamond Corp.www.brucediamond.com

Cdp Diamond Products Inc.www.cdpdiamond.com

CemeCon, Inc.www.cemecon.com

Chardon Tool & Supply Co., Inc.www.chardontool.com

Continental Diamond Tool Corp.www.cdtusa.net

Crystallume EngineeredDiamond Productswww.crystallume.com

Cutting Edge Services Corporationwww.cuttingedgeservices.com

Decatur Diamond, LLCwww.sp3cuttingtools.com

Delaware Diamond Knives Inc.www.ddk.com

Desmond-Stephen Mfg. Co.www.desmond-stephan.com

Dev Industrial Corp.www.dev-group.com

Diamond Industrial Toolswww.todit.com

Dianamic Abrasive Products Inc.www.dianamic.com

DiCoat Corporationwww.dicoat.com

Eastwind Lapidary, Inc.www.eastwinddiamondabrasives.com

Element Sixwww.e6.com

Engis Corp.www.engis.com

FACT Diamondwww.factdiamond.com

FACT USAwww.wmstrading.com

Fives Landis Corp-Citco/Gardnerwww.fivesgroup.com

Fort Wayne Wire Die Inc.www.fwwd.com

Garden Colors LLCN/A

Greenlee Diamond Tool Co.www.greenleediamond.com

The Grinding Docwww.TheGrindingDoc.com

HK Technologieswww.clevelandvibrator.com

Iljin USA, Inc.www.iljindiamond.com

Industrial Diamond Laboratories Inc.www.industrialdiamondlabs.com

K & Y Diamond Ltdwww.kydiamond.ca

Lach Diamond, Inc.www.lachdiamond.com

Lands Superabrasives Co.www.landssuperabrasives.com

Lieber & Solow Co.www.lieberandsolow.com

Megadiamond Inc.www.megadiamond.com

Morgan Advanced Materials andTechnologywww.morganplc.com

MWI Eloquence Corporationwww.mwieloquence.com

National Research Co.www.nationalresearchcompany.com

Niabraze Corp.www.niabraze.com

Noritake Co Inc.www.noritake.com

Pinnacle Abrasiveswww.pinnacleab.com

Precision Eformingwww.precisioneforming.com

Protech Diamond Tool Inc.www.protechdiamondtoolsinc.com

Radiac Abrasives Inc.A Tyrolit Companywww.radiac.com

Rollomatic, Inc.www.rollomatic.ch/en/contact/usa

Sandvik Hyperionwww.hyperion.sandvik.com

Saint-Gobain Surface Conditioning Group(Saint-Gobain Ceramic Materials)www.innovativeorganics.com

Scio Diamond Technologywww.sciodiamond.com

Spec Toolwww.spec-tool.com

Standard Die & Fabricating Inc.www.standarddie.com

Sumitomo Electric Carbide Inc.Materials Groupwww.sumicarbide.com/diamondgroup

Superabrasives Inc.www.superabrasives.com

Syntech Abrasives Inc.www.syntechabrasives.com

Tomei Corp. of Americawww.tomeidiamond.com

Ulbrich Stainless Steels & Special Metals, Inc.www.ulbrich.com

US Synthetic Corporationwww.ussynthetic.com

Vollmer of America Corporationwww.vollmer-us.com

Wemex Superabrasivos, S. DE R.L. DE C.V.www.wemex.com.mx

Worldwide Solids, LLCA Division of Worldwide Superabrasives, LLCwww.worldwidesolids.com

Worldwide Superabrasives, LLCwww.worldwidesa.com

YG-1 USAwww.yg1usa.com

Zhongnan Diamond Co., Ltdwww.diamond-zn.com

INDUSTRIAL DIAMOND ASSOCIATION OF AMERICA (IDA)MEMBER COMPANIES

Contact an IDA Member Company for superior products and services related to the superabrasives and ultra-hard materials industry. IDA Members follow a strict code of ethics to guarantee quality and dependability.

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A Study on FractureCharacteristics of MicronDiamond Powders UnderStatic High PressureConditionsION C. BENEA, PH.D., BENJAMIN R. ROSCZYKEngis CorporationWheeling, IL 60090, USA

CONCLUSIONSIn this paper, we presenta novel technique andthe associatedapparatus developed toassess the crushingstrength (expressed ashigh pressure crushingstrength index, HP-CSI)and mode (expressed asthe amount and sizedistribution of fneparticles generated),following high pressuretreatment of theprecursor microndiamond powder usedfor HPHT sintering ofpolycrystalline diamondcompacts (i.e. PDCcutters for oil and gasdrilling, PDC tool blanksand dies, etc.Anopposed high pressureapparatus, whichincorporates a pair ofPDC-WC compositeanvils, was developed tosimulate the highpressure environment,experienced by microndiamond powder duringpressure ramp-up inHPHT sintering processof PDC.

ABSTRACTThe manufacturing process of polycrystalline diamond compacts(PDC) consists primarily in sintering of micron size diamondparticles into a coherent and homogeneous polycrystalline diamond (PCD) layer on topa tungsten carbide substrate, under high pressure and high temperature conditions (i.e.P > 5.5 GPa; T > 1,400 oC).

During ramp-up to sintering pressure at room temperature, many diamond particles arecrushed, due to compression and shear stresses. Thus, subsequent to pressure ramp-up, particle size distribution of the precursor micron diamond powder withstands asignificant change.

Consequently, besides the HPHT sintering process, fracture characteristics (fracturestrength and mode) of precursor micron diamond powder used for high pressure-hightemperature (HPHT) sintering of PCD layer, may have a critical contribution to impactstrength and abrasion resistance of polycrystalline diamond compacts (i.e. PDC cuttersfor oil and gas drilling, PDC tool blanks and dies, etc.).

Current technique used to assess the fracture strength and mode of micron diamondpowders is based on subjecting the micron diamond powder sample to mechanicalforces similar to those encountered in the lapping process [1, 2]. This technique isbased on crushing a, virtually, single layer of diamond particles between two sinteredpolycrystalline diamond surfaces, which rotate in opposite direction, under lowcompressive force. Thus, larger particles are crushed, mainly due to shear stresses,while smaller particles are not crushed.

The objective of this study is to develop a high pressure apparatus designed to studythe fracture characteristics of micron diamond powders under high pressure, and theassociated technique to measure the crushing strength of micron diamond powderunder static high pressure conditions, corresponding to those used for HPHT sinteringof PDC. The crushing strength was investigated by subjecting different micron sizediamond powder samples to static high pressure conditions. Prior to high pressuretreatment, micron size diamond powder samples were characterized with respect toparticle size, particle shape and concentration of crystalline defects. After high



HIGH SPEED ROUTING HIGHLYABRASIVE MATERIALS WITH

CVD DIAMOND CUTTING TOOLSTUFFY K.1, DONTU G.2, ENGELS A.1& NOVAK C.2

NanoDiamond Products DAC, Shannon, IrelandFives Landis Corp. – CITCO Tools, Ohio, USA

Abstract: Thick film chemically vapourdeposited (CVD) diamond films haveextreme wear resistance, exceptional

thermal conductivity and can beattached to tool bodies using

commercially viable brazing techniques.Cutting tools fabricated with CVD

diamond materials are done so moreeasily today using laser processes andoften in conjunction with superabrasive

grinding. The properties of extremewear resistance make CVD diamond

ideally suited to the new challenges ofthe cutting tools industry today of

difficult to machine materials, includingcomposites. This paper will outline theadvances in CVD diamond technologyand associated processing making it

suitable for defined edged applicationsin continuous and interrupted cutting.

In addition, a case study will beoutlined demonstrating the type of

performance possible when high speedrouting carbon fibre reinforced

plastic composites.

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INTRODUCTIONUnsurpassed hardness of diamond and associated wearresistance is one the most important properties whenconsidering its use as an abrasive [1]. The majorcontributing factors to the extreme hardness of diamond arethe tetrahedral geometry of the crystalline structure with onlyC-C covalent bonds and elastic constants in all directionsthat are among the highest of any material [2]. Diamond alsohas outstanding thermal conductivity due to phonon transferand very stiff hybridized sp3 bonds, although the specificthermal conductivity of a diamond crystal is dependent onthe origin of the diamond, monocrystal or polycrystallinitystructure and the crystal purity [3].

Natural diamond is typically the result of volcanic processescontaining kimberlite but the resultant diamond crystals canbe found in volcano shafts or basically wherever nature hasre-distributed the volcanic lava [4]. Commercial quantities ofsynthetic diamond can be produced using static anddynamic compression (direct or with catalysts) or by usingchemical vapour deposition (CVD) [5]. Polycrystallinediamond free standing films produced with chemical vapourdeposition (CVD) are produced in the metastable region fordiamond since it occurs at low pressures.

Diamond products, consisting of a matrix of cobalt, withmicron sized particles of diamond on a tungsten carbidesubstrate are commonly referred to as polycrystallinediamond (PCD) or a polycrystalline diamond compact. PCDis produced using static high temperature pressureprocesses and due to the presence of cobalt is electricallyconductive [6]. Many variants exist and the particle sizedistribution of the diamond in the cobalt matrix can vary from0.5 microns to 50microns or multimodal combinations ofvarious grain sizes. PCD finds widespread use today in thecutting tool industry as well as in the oil and gas exploration,drilling and mining industries.

Although CVD diamond has been synthesized from the gasphase since the 1950’s [7], thick film CVD diamond hasfailed to find a broad acceptance in the cutting tool industry,although has been used extensively in diamond dressingtools. Polycrystalline diamond CVD thick films can beproduced using hot filament or plasma processes, but theCVD process used, as well as the selection and processingof the produced diamond film all have major implications onthe performance of the cutting tool. The ideal properties of acutting tool, their coatings and performance is discussed in


Active BrazingMethods for JoiningThermally StableDiamond Composites

Author – THOMAS C. EASLEY, Ph.D.Presenter – ABDS-SAMI MALIK, Ph.D.

Sandvik Hyperion

ABSTRACTSeveral experiments were conducted to determine theeffects of alloy composition, test temperature, brazingatmosphere, thermal residual stress, and use of Cuinterlayers on the strength of braze attachment ofsilicon carbide diamond and tungsten carbide. Alloys inthe Ag-Cu-In-Ti system with brazing temperaturesbetween 650°C and 920°C were evaluated. All alloysproduced good quality braze joints with shear strengthsover 250MPa. The results show that thermal residualstresses lower the braze joint strength considerably.Strength can be increased by using alloys with lowerbrazing temperatures.The use of ductile Cuinterlayers can reduceresidual stresseswithout loweringbraze shear strength.

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I N T R O D U C T I O NSilicon carbide/diamond composites (SCD) comprise a rangeof materials consisting of diamond particles bonded within asilicon carbide (SiC) matrix. The composites are formed byinfiltrating diamond particles with liquid silicon. Siliconreacts with diamond to form silicon carbide in which thediamond particles are embedded1. Commercially availableSCD have diamond content ranging from 20% to 80% byvolume. These materials can be produced using sinteringconditions ranging from atmospheric pressures up to 8 GPaand at temperatures ranging from 900 to 1600°C. They aretypically formed as monolithic solids, with no supportingsubstrate.

SCD are prized for their high hardness, abrasion resistance,and thermal stability. SCD produced using high pressure –high temperature (HPHT) apparatus can have diamondcontent over 80% by volume and have double the strength(TRS) and toughness (KIc) of other engineered hard ceramicmaterials such as boron carbide (B4C) and silicon carbide(SiC), making them attractive candidates for manyapplications requiring a combination of mechanical durabilityand wear resistance in extremely abrasive environments.However, their widespread use has been hindered due tolimitations in brazing technology. To successfully use thesematerials in applications, they usually must be joined to asuitable supporting substrate, most commonly tungstencarbide (WC). Due to the very low coefficient of thermalexpansion (CTE) of SCD (~2 x 10-6) compared to WC (4 to 6 x10-6), thermally induced residual stresses will be present in thebrazed articles, which may lead to reduced strength orcracking.

In this study, active braze alloys, containing titanium, havebeen investigated for joining SCD to WC. The braze alloycompositions were chosen based on their ability to wetdiamond surfaces by the formation of TiC at the SCD surface,and form strong bonds between the alloy, SCD, and WCcomponents. The SCD used in this work was Versimax™,which has a typical diamond particle size of 20mm, diamondcontent of 80% by volume, TRS of 935MPa, and KIc of 9.5MPa(m)1/2. The material is electrically conductive, allowing itto be easily machined using electrical discharge machining(EDM) processes. The brazing and braze shear strength resultspresented here will be generally applicable to other SCDmaterials and thermally stable diamond composites becausethe same surface reaction forming TiC from Ti and diamondwill occur, although the properties of the resulting tool willvary greatly depending on the properties and quality of theSCD material.

The good thermal stability of Versimax™ SCD lends it to usein high temperature applications. At elevated temperatures,two competing mechanisms operate which affect the shearstrength of braze joints. At elevated temperatures, the brazemetal will soften, reducing its strength. However, thermalresidual stresses will be reduced at higher temperatures, whichmay result in higher joint strength. Therefore, there is a needto better understand the mechanical behavior of SCD-WCjoints at elevated operating temperatures.

E X P E R I M E N TA L M E T H O D SBraze filler metals, in the form of paste or foil, werepurchased from Morgan Advanced Materials and Prince-Izant.Brazing was conducted using a vacuum level of < 5 x 10-5 Torror under inert argon atmosphere, and temperatures rangingfrom 650 to 920 °C. The temperature for brazing wasspecified by the manufacturer. Braze coupons were weightedduring brazing with > 1 g/mm2. The braze alloys are listed inTable 1, and the alloy compositions are given in Table 2.



Author – Dr. KARL MAYRHOFER, R&D Resin and Metal Bonds, TYROLIT, AustriaPresenter – CHRISTOPHER GOLSER, Sr. Application Engineer, RADIAC ABRASIVES, USA

Modern indexable inserts consist of hard materials (tungstencarbide, cermet, ceramic, polycrystalline diamond (PCD),polycrystalline cubic boron nitride (PCBN)) and are usually groundafter sintering to precise shape and dimensions with diamondgrinding wheels. Face grinding of the periphery (clearancesurface) of the inserts is a very time consuming step besidesgrinding the radii and a possible chamfer due to the high stockremoval. Resin, metal and vitrified bonded diamond wheels havebeen used usually over the last decades. Because the wheels areclogging, loading, wearing und losing shape, they have to bedressed conventionally using wheels made of silicon carbide (SiC)or aluminum oxide (Al2O3) for cleaning and restoring a flatsurface geometry.

This paper presents a new generation of metal bonded grindingwheels which are dressed in process using electrical dischargeconditioning (EDC). This combined process called “PowerGrind”was developed and introduced by the machine builder Agathon,Switzerland. There are some basic requirements to grindingwheels dressed by electrical discharge conditioning:

Firstly, a highly electrical conductance of the diamond wheel isnecessary: Due to he high current flow (up to 60 Amperesdischarge current, discharge time 1-2µs) during the electricaldischarge the body (carrier) of the wheel, the rim and the interface(glue or thin copper layer) between the body and the diamondlayer have to be electrical conductive. It was found out, that theresistance between the diamond layer and body should be lowerthan 20mΩ, respectively the conductance should be greater than50S. Usually the rims are glued on aluminum cores which have asufficient specific electrical conductivity (38*106 S/m).

Secondly, the bond must be machinable by EDC in order to dress,sharp and clean the grinding wheel. In consequence metal bondwith a low melting temperature is preferred for a controlled wheelwear. Theoretically, a conductive highly metal (e.g. copper) filledresin bond diamond wheel could be conditioned by EDC. But dueto the locally high temperature (T > 4000 K) caused by the sparkdischarges, the resin bond would be decomposed. Also aelectrical conductive ceramic bond would work.

Thirdly, there are some requirements due to the grinding process:The grinding parameters (peripheral speed, infeed, stock) and the

This paper presents a new generationof metal bonded grinding wheelswhich are dressed in process usingelectrical discharge conditioning

(EDC). This combined process called“PowerGrind” was developed andintroduced by the machine builder

Agathon, Switzerland.


SKYTEC BOLT – A NEW GENERATION of metal bonded diamond wheels for grinding of indexable inserts with electrical discharge conditioning

Cutting DiamondTools By LaserMicroJet®

New developments in the wet lasermachining of industrial diamond tools

SÉBASTIEN KURZEN, NITIN SHANKAR

LMJ PROCESSIn the Laser MicroJet system, a laser beam,passing through a pressurized water chamber, isfocused into a nozzle. The low-pressure water jetemitted from the nozzle guides the laser beam bymeans of total internal reflection at the water/airinterface. The water jet diameter is usually 50microns and the laser power required is between25 and 30 watts. While the principle looks simple,years of experimentation and optimization wererequired to fine-tune the process. The LMJprocess works in two stages. The energy of thelaser pulses vaporizes the workpiece material byheating while the water cools and cleans thesurface in the interval between the pulses.Through a scanning process, a trench is formedthat becomes deeper with each pass. Ascompared to traditional dry lasers, the LMJ “wetlaser” technology has many advantages. Themost important advantage is that Laser MicroJetcuts with a parallel beam and the cutting depthcan extend up to several centimetres. This is notthe case with conventional lasers where thefocused laser beam has a limited workingdistance of just a few millimetres due to beamdivergence. The beam converges at a focal pointand then diverges. Therefore, a focus distance control is required and theworking distance is short. The technology behind the Laser MicroJet is basedon creating a laser beam that is completely reflected at the air-water interface,using the difference in the refractive indices of air and water. The laser is,therefore, entirely contained within the water jet as a cylindrical beam, similarin principle to an optical fibre. The LMJ process offers several advantages.There is no need for focal adjustment and one obtains parallel kerf sides.There is a minimum heat affected zone thanks to the cooling effect of thewater. Finally, there is a high removal rate with debris washed from the kerf.Synova LCS 50-5 Laser Cutting System The Synova LCS 50-5 laser cuttingsystem can cut extremely hard materials with high precision. It is a compact


INTRODUCTIONArtificial diamond materials arereplacing tungsten carbide andceramic composites in cuttingtools where high surface finishquality is required. The choice ofmaterials ranges from lower endpolycrystalline diamond (PCD) tohigh-end single crystallinediamond (SCD). SCD tools haveproven their capability in thesuper-finishing of ultra-precisionoptical grade surfaces. In manycases, the use of SCD tool insertscan eliminate grinding operationsand cut process times. They alsobenefit from a longer tool life. Onlylaser technologies are capable ofmachining such materials, whichare just as hard as naturaldiamonds. Synova•s patentedLaser MicroJet® (LMJ) technologydelivers better results thantraditional dry lasers and isespecially suited for the machiningof diamond materials. This papershows the results achieved inusing Synova•s Laser MicroJetprocess for cutting PCD and SCDtool inserts.

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Measurement of Residual Stress ofPolycrystalline Diamond Cutter (PDC) by X-ray Diffraction TechniqueD.K. MUKHOPADHYAY and K.E. BERTAGNOLLIUS Synthetic Corporation260 South 1600 West, Orem, Utah, 84058, USA

IntroductionSince their introduction over 30 years ago, polycrystalline diamond cutters (PDC)have made a significant impact on the oil and gas drilling industry [1]. Highpenetration rate and long life are some of the attributes of PDC bits. However, PDCcutters may fail prematurely during hard rock drilling. Fig 1. shows a typical PDCfailure mode which may be attributed to residual stress. Conventional PDC insertsare made by sintering diamond powder on a cobalt-cemented tungsten carbide(WC-Co) substrate under high pressure-high temperature (HPHT) conditions around6 GPa and 1400°C. During sintering, cobalt from the substrate melts and infiltratesthrough the pores among the diamond crystals, producing a zone of depleted cobaltin the substrate near the interface. The molten cobalt dissolves carbon atoms fromthe diamond crystals and quickly saturates. The dissolved carbon precipitates andforms diamond-diamond bonding among the diamond crystals [2]. As the pressureis released and the PDC cools from sintering, the diamond layer and the carbidesubstrate shrink at different rates, thus giving rise to residual stress in the PDC. Thereare several techniques to measure residual stress in PDC [3]. Diffraction methodsinclude X-ray diffraction (XRD), neutron diffraction, synchrotron X-ray, and Ramanscattering. Diffraction techniques are generally non-destructive methods of residualstress measurement in PDC. Both neutron and synchrotron techniques have highpenetration depth in comparison to X-ray diffraction or Raman but they need special

KEYWORDS:• Polycrystalline

Diamond Cutter

• XRD

• Residual Stress

• HTHP

• Tilt Angle

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Industrial Diamond Association of America, Inc.

MEMBERSHIP APPLICATIONCompany _____________________________________________________ Address________________________________________________________________City ____________________________________________ State _______ Zip Code/Postal Code ______________ Country _________________________________Shipping Address (Can not ship to PO Box)__________________________________________________________________________________________________City ____________________________________________ State _______ Zip Code/Postal Code ______________ Country _________________________________Phone ________________________________________________________ Fax __________________________________________________________________E-mail ________________________________________________________ Web Site ______________________________________________________________Official Representative __________________________________________________________________________________________________________________Others (Participating in IDA Activities) ______________________________________________________________________________________________________Principle Business Activity_______________________________________________________________________________________________________________Which applies to your company: _______ Corporation _______ Partnership _______ Sole ProprietorshipProvide names of principle officers or partners: _______________________________________________________________________________________________When was your company established? __________ List at least two business references which are current IDA REGULAR MEMBERS. REQUIRED for Consideration

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_______ Regular MembershipAny company and/or individual classified as a superabrasive/ultra-hard material supplier, tool maker, machine tool builderor related business which HAS an office and a local, state or province business license in the United States, Canada orMexico is eligible for membership in this category. Only one individual shall be designated by each member company asthe IDA Delegate with voting and other privileges described in the By-Laws.

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______ International MembershipAny company and/or individual in the diamond and/or cBN business which DOES NOT have an office and a local, state orprovince business license in the United States, Canada or Mexico is eligible for membership in this category. AnInternational member shall have all the privileges of regular membership, except that he/she cannot vote at anymembership meetings, participate in statistical reporting for the North American market, hold proxies or serve in any office inIDA. Annual fee for International Member is $3990 per year.

_______ Associate MembershipAvailable for companies having a principal office in the U.S.A., Canada or Mexico, which are providing products orservices to companies within the superabrasive/ultra-hard material industry, but are not engaged in selling, using ordealing in industrial diamonds, cubic boron nitride, compacted diamond/cbn, diamond film or products containingdiamonds/cbn. An Associate member shall have all the privileges of regular membership. Annual fee for an Associate is$600 per year.

_______ End User/Contractor MembershipAvailable for any global companies or individuals, which USE products classified as superabrasives or ultra-hard materials,but are NOT ENGAGED IN SELLING industrial diamonds, cubic boron nitride, compacted diamond/cbn, diamond film orproducts containing diamonds/cbn. An End User/Contractor member shall have all the privileges of regular membership,except that the Delegate cannot vote at any membership meetings, participate in statistical reporting for the North Americanmarket, hold proxies or serve in any office in IDA. Annual fee for an End User/Contractor is $400 per year.

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_______ Student MembershipAny FULL TIME Student NOT ENGAGED IN SELLING industrial diamonds, cubic boron nitride, compacted diamond/cbn,diamond film or products containing diamonds/cbn is eligible for membership in this category. A Student shall have all theprivileges of regular membership, except that he/she cannot vote at any membership meetings, participate in statisticalreporting for the North American market, hold proxies or serve in any office in IDA.Annual fee for a Student Membership is$100 per year.

_______ Senior MembershipAny individual who has worked for and/or retired from an IDA Member company or is no longer active in the diamond orCBN business is eligible for membership in this category. A senior member shall have all the privileges of regularmembership, except that he/she cannot vote at any membership meetings, participate in statistical reporting, hold proxies orserve in any office in IDA. Annual fee for a Senior is $75 per year.

Name of Delegate Member:___________________________________________________________________________________

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* Applications for ALL Memberships are reviewed by the Board of Directors and must be approved by a two-thirds vote.

_______ Affiliate MembershipEach company that enrolls as an IDA Member is entitled to have a second person at that company designated an AffiliateMember. The first Affiliate member will receive IDA material at no further cost. Additional persons at Member companies canbe added as Affiliate Members to receive IDA materials. Annual fee for additional Affiliates is $100 per person. Name of 1stAffiliate Member (no charge):

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WHAT IS THE IDA?The Industrial Diamond Association ofAmerica, Inc. is a non-profit tradeassociation and was incorporated onMarch 29, 1946 in the State of New York.It is the oldest and most prestigiousassociation in the superabrasive/ultrahardmaterials industry. Activity and focus hasevolved from natural diamond tosuperabrasives and most recently, to allultrahard materials including CVDDiamond. Members include materialsuppliers, tool manufacturers, componentproducers, machine tool builders, endusers, academia/research affiliates andother companies related to the research,manufacture, application, use and sales ofsuperabrasives.

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2017 EDITORIAL CALENDARPlanned issues, topics and closing dates*:

Issue: Editorial Feature*: Closing

Summer 2017 INTERTECH 2017 Review& Paper Synopsis June 1, 2017

Fall 2017 Superabrasives Education Sept. 1, 2017

Winter 2017/2018 Superabrasive IndustryOverview Dec. 1, 2017

Spring 2018 New Technology andApplications Mar. 1, 2018

Summer 2018 Machine Tools & IMTSPreview June 1, 2018

*Editorial topics & closings subject to change

SHIPPING INSTRUCTIONSFax, mail or email all printing materials to:

Production ManagerFINER POINTS MAGAZINE

P.O. Box 29460 • Columbus, Ohio 43229 USAPhone: 614-797-2265 • Fax: 614-797-2264

E-Mail: [email protected]

FinerPointsSUPERABRASIVE INDUSTRY REVIEW

New Orleans has many visitor attractions,from the world-renowned French Quarter; toSt. Charles Avenue, (home of Tulane andLoyola Universities, the historicPontchartrain Hotel, and many 19th-centurymansions); to Magazine Street, with itsboutique stores and antique shops.According to current travel guides, NewOrleans is one of the top ten most-visitedcities in the United States. A recent poll of"America's Favorite Cities" ranked NewOrleans first in ten categories, the most first-place rankings of the 30 cities included.According to the poll, New Orleans is thebest U.S. city as a destination and for stylishboutique hotels, cocktail hours, singles/barscenes, live music/concerts and bands,antique and vintage shops, cafés/coffeebars, neighborhood restaurants, and peoplewatching. The city also ranked second forfriendliness, hotels/inns, and ethnic food.The French Quarter (known locally as "theQuarter" or Vieux Carré), which was thecolonial-era city and is bounded by theMississippi River, Rampart Street, CanalStreet, and Esplanade Avenue, containsmany popular hotels, bars, and nightclubs.

Notable tourist attractions in the Quarterinclude Bourbon Street, Jackson Square, St.Louis Cathedral, the French Market(including Café du Monde, famous for caféau lait and beignets), and Preservation Hall.Also in the French Quarter is the old NewOrleans Mint, a former branch of the UnitedStates Mint which now operates as amuseum, and The Historic New OrleansCollection, a museum and research centerhousing art and artifacts relating to thehistory of New Orleans and the Gulf South.To tour the port, one can ride the Natchez,an authentic steamboat with a calliope,which cruises the Mississippi the length ofthe city twice daily. Unlike most other placesin the United States, New Orleans hasbecome widely known for its element ofelegant decay. The city's historiccemeteries and their distinct above-groundtombs are attractions in themselves, theoldest and most famous of which, SaintLouis Cemetery, greatly resembles PèreLachaise Cemetery in Paris. The city andarea boosts numerous museums andattractions of major interest and historicalvalue. New Orleans rankedNo. 7 on Newsmaxmagazine's list of the "Top 25Most Uniquely AmericanCities and Towns," a piecewritten by current CBS Newstravel editor Peter Greenberg.In determining his ranking,Greenberg cited the city'srebuilding effort post-Katrinaas well as its mission tobecome eco-friendly. TheNew Orleans area is home to

numerous celebrations, the most popular ofwhich is Carnival, often referred to as MardiGras. Carnival officially begins on the Feastof the Epiphany, also known as the "TwelfthNight". Mardi Gras (French for "FatTuesday"), the final and grandest day offestivities, is the last Tuesday before theCatholic liturgical season of Lent, whichcommences on Ash Wednesday. The largestof the city's many music festivals is the NewOrleans Jazz & Heritage Festival. Commonlyreferred to simply as "Jazz Fest", it is one ofthe largest music festivals in the nation,featuring crowds of people from all over theworld, coming to experience music, food,arts, and crafts.


Every INTERTECH is a new experience in location andtechnological undertaking, 2019 holds the promise of aneven greater event! In 2019 the Industrial DiamondAssociation of America welcomes the world to theINTERTECH in New Orleans, Louisiana USA.

COMING in 2019!

Progresses of Grinding Technology of MonocrystallineSilicon Carbide; for Longer Tool Life and Higher

Quality Finished SurfacesShuichi AMINO, Tomohiro ISHIZU, Nobuhide NAKAMURA, and Toshiya TAKAHASHI

A.L.M.T. Corp. • 1816-174 Kotaka, Kato City, HYOGO 679-0221, JAPAN

ABSTRACTIn order to accelerate the massproduction of SiC power semiconductordevices, which possess a higherperformance than Si based powersemiconductor devices, lowering themachining cost and obtaining higher-quality finished surfaces in the waferthinning process are crucial. This paperwill introduce the latest progresses ofgrinding technologies of SiC wafers,which can significantly reduce themachining cost and improve the qualityof finished surfaces.

INTRODUCTIONPower semiconductor devices and SiCDue to the growing concern of energydepletion, power semiconductor devicesthat enable more efficient use ofelectricity in many fields such asautomobiles, trains, and power grids, aregathering more attention and projected

to be increasingly prevalent. Currently,the most commonly used material forpower semiconductor devices is silicon(Si). However, the performances of Si-based power semiconductor devices havealmost reached the limitation of thephysical property of Si, and it is said thatit cannot meet the forthcomingrequirements for power semiconductordevices, e.g., higher operatingtemperature and voltage resistance.Silicon carbide (SiC), on the other hand,possesses superior physical propertiesand is considered as a more promisingmaterial for next-generation powersemiconductor devices. By employingSiC, power semiconductor devices canwork in the said severeconditions andreduce the lossesof electricitythanks to its highswitchingperformance.



Patents – a key facet of IPprotection for the superabrasive/industrial diamond industry

DUSTIN JOHNSON AND KEVIN HARDAWAY*Haynes and Boone LLP

Patent filings continue to increase each year in the UnitedStates and across the developed world. Many developers in

the superabrasive industry use patents to protect theirinvestment and obtain strong market positioning.

Fundamental Patent Principles and Rights GrantedOf the different types of intellectual property, patents and tradesecrets are best suited for most inventions in the superabrasiveindustry. Each has advantages and disadvantages. Trade secretprotection is best suited for intellectual property that cannot be easilyreverse engineered. Trade secrets have no expiration date, butrequire reasonable efforts to protect against disclosure. So long ascompetitors do not develop the same product, trade secret protectionmay be a good avenue to protect intellectual property. Manycorporations, however, employ business strategies that includereverse engineering or otherwise copying successful products.

Patents can protect products and processes that may be reverseengineered. They provide a limited monopoly to a patent holderenabling them to prevent others from making, using, selling, offering

Complete Paper Available on INTERTECH2017 Proceedings Download Link • Order

at www.intertechconference.com


PCD Bits forUNDERGROUNDRoof Bolting

Author – L.F. GARCIA, Ph.D.Presenter – ABDS-SAMI MALIK, Ph.D.

Sandvik Mining and Construction G.m.b.H

ABSTRACTThis work first describes briefly some of the roof boltingtechnologies available in the market for soft and hard rockconditions. For targeting particularly roof bolting in coal mines,Sandvik has developed a new PCD drill bit line giving anincrease in performance productivity for Sandvik continuousbolter miners. Experimental work during product developmentwas mainly carried out by laboratory drilling with oneinstrumented Sandvik DO100 drill-rig and incrementalimprovements were observed by analyzing drilling parametersdata logs, bit failure mechanisms and estimated total bit lifetime.PCD characteristics including different finishing conditions weretested and analyzed. A final design was qualified at thelaboratory and confirmation with mine field tests collected. Testsbeyond the original target are highlighted including hard-rockgranite drill experiments with an adapted Sandvik Axera 5 atSandvik´s Tampere test mine in Finland.

INTRODUCTION Roof bits are used to drill holes in the strata before anchoringbolts are utilized to secure the roof of mines. The first applicationof diamond for roof bits dates to more than 20 years ago [Brady],

[Sheirer et al.]. Originally those bits were targetedfor North American coal mines trying to replacetraditional carbide bits. The main objective forusing PCD was to extend the life of the tools andsimplify the logistics of the operations by reducingthe number of bit-changes per time period. Theperceived reliability of operation by the customershas been the main problem for extending the usageof these drill bits.

DRILLING FOR ROOF BOLTING Two types of roof bolting technologies existprimarily based on the rock type to be drilled. Forhard rock mines like copper or platinum mines,roof rock drilling with percussion bits has shown tobe the most economical choice. For more soft rockslike coal or potash/salt mines pure rotary drilling isused since higher drilling speeds are theoreticallyachievable [Feistkorn]. The drilling equipment andconsumable tools are more economical for the case



finer points · from intertech 2017 technical ... (e.g., grinding wheels, dressing tools, drill...

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