Selection and Application of Single Crystal Diamond Tool Crystal Faces

1. Diamond crystal face Introduction

Single crystal diamond is widely used in ultra-precision machining due to its extreme hardness, wear resistance, and excellent thermal conductivity. However, different crystal faces exhibit distinct atomic arrangements, bonding energies, and wear properties, making the selection of the appropriate crystal face crucial in tool design. This article explores the characteristics of different single-crystal diamond faces and their applications in machining, providing users with a scientific selection guide.

2. Characteristics of Diamond

Crystal Faces Diamond belongs to the cubic crystal system, and its anisotropic properties result from variations in atomic structure across different crystal faces. The primary crystal faces include (100), (110), and (111), with (100) and (110) being the most commonly used in single-crystal diamond tools.

100 Face: Features a uniform atomic arrangement with low bonding energy, making it the most resistant to breakage. Has relatively lower hardness and moderate wear resistance. Suitable for high-precision machining, such as optical glass, semiconductor wafers, and precision molds.

110 Face: Exhibits higher atomic density and bonding energy, making it more susceptible to external forces. Possesses high hardness and excellent wear resistance. Suitable for high-intensity machining, such as metals, ceramics, and hard-brittle materials.

3. Selection Principles for Single Crystal Diamond Tool Crystal Faces

Selecting the appropriate crystal face for different machining applications can enhance tool life and improve machining accuracy.

High-precision, low cutting force machining (optics, semiconductors) Choose the (100) face for both the rake and flank faces to reduce cutting resistance and achieve high surface quality.

High-strength, high-wear-resistance machining (metals, ceramics)

Use the (110) face for both the rake and flank faces to improve mechanical wear resistance. hemical wear-resistant machining (special materials)

Apply the (110) face for the rake face to enhance oxidation resistance, while selecting the (100) face for the flank face to reduce mechanical wear.

4. Typical Application Cases of diamond crystal face selection

Case 1: Precision Machining of Optical Glass A manufacturer of optical glass utilized single-crystal diamond tools for ultra-precision turning, employing the (100) face for both the rake and flank faces. This resulted in low cutting force and a glass surface roughness (Ra) as low as 10 nm, meeting high-end optical lens requirements.

Case 2: Hard Alloy Mold Processing A mold manufacturing company used diamond tools to process tungsten carbide molds, selecting the (110) face for both the rake and flank faces. This choice increased tool wear resistance by 30% and doubled tool life.

Case 3: Sapphire Substrate Cutting In the semiconductor industry, sapphire substrate cutting requires tools with high hardness and minimal damage. Using a rake face of (110) and a flank face of (100) provided a balance between wear resistance and cutting stability.

 Conclusion

The performance of single-crystal diamond tools is closely related to the selection of crystal faces. A rational choice of crystal face can enhance tool longevity while optimizing machining quality and efficiency. In precision machining, metalworking, and hard-brittle material processing, selecting the appropriate diamond crystal face according to material properties and machining requirements maximizes the advantages of single-crystal diamond tools.