ASSIGNMENT
PREPARED BY,
KARTHICK.N
2009606001
M.E. MANUFACTURING ENGG
ANNA UNIV – MIT, CHROMPET.
CONTENTS
1. CUBIC BORON NITRIDE
1.1. INTRODUCTION
1.2. ORIGIN
1.3. GENERAL DETAILS
1.4. PROPERTIES
1.4.1. CRYSTALLOGRAPHIC PROPERTIES
1.4.2. MECHANICAL PROPERTIES
1.4.3. THERMAL PROPERTIES
1.4.4. THERMODYNAMIC PROPERTIES
1.4.5. ELECTRIC PROPERTIES
1.4.6. CHEMICAL REACTIVITY
A. WITH METALS
B. WITH OXIDES
C. WITH ACIDS AND BASES
D. WITH BIOLOGICAL SYSTEMS
1.5. APPLICATIONS
1.5.1. CUTTING TOOL APPLICATIONS
1.5.2. OTHER APPLICATIONS
1.6. CBN TYPICAL MACHINING PARAMETERS
1.7. ADVANTAGES
1.8. DIFFERENT OPERATIONS USING CBN
1.9. POSSIBLE CRYSTAL STRUCTURES OF CBN
1.10. STRUCTURE OF A CBN WHEEL OF AN ESTABLISHED COMPOSITION
1.11. RELATIVE STRENGTH OF THREE REPRESENTATIVE CBN GRADES
AFTER HEAT TREATMENT AT DIFFERENT TEMPERATURES
1.12. SPLINTER SIZE OF THREE REPRESENTATIVE CBN GRADES
AFTER HEAT TREATMENT AT DIFFERENT TEMPERATURES
1.13. DIFFERENT GRADES OF CBN
1.14. COMPARISONS OF SOME CBN PRODUCTS AVAILABLE IN MARKET
2. POLY-CRYSTALLINE DIAMONDS
2.1. INTRODUCTION
2.2. NATURAL PCD
2.2.1. PROPERTIES
2.3. ARTIFICIAL PCD
2.3.1. FABRICATION
2.3.2. PROPERTIES
2.4. APPLICATIONS
2.5. MANUFACTURING DIFFERENT SHAPES OF PCD
2.6. DIFFERENT SIZES OF PCD IN USED VARIOUS APPLICATIONS
2.7. PHYSICAL PROPERTIES OF SOME PCD PRODUCTS
2.8. ADVANTAGES
2.9. DISADVANTAGES
3. REFERENCES
1. CUBIC BORON NITRIDE
1.1. INTRODUCTION:
1.2. ORIGIN:
The cubic form was only realised after the discovery, in 1957, by R. H.
Wentorf Jr. of the General Electric Company, USA, that the hexagonal form
could be transformed to the cubic by the use of high temperatures and
pressures.
TABLE - 1
Properties of all the materials arise from their structure, i.e., from the
manner in which their atoms aggregate into hierarchies. Let us see the various
properties of cubic boron nitride here.
Colourless (rare);
Generally, yellow (amber, honey, cinnamon), orange,
black (B-doped),
Colour
brown, deep blue (Be-doped).
Yellow and orange crystals are thermo chromic and become
opaque about 450 °C.
Cubic
Crystal system
Structure type Zinc blende
Atoms/unit cell 4B, 4N
Lattice constant (25 °C) [nm] 0.3615 ± 0.0001
Ionic distance (B-N) [nm] 0.157
3.48 calculated from X-ray data
Density [g/cm3] 3.45 measured data
truncated tetrahedra or octahedra {111}
hexagonal plates {111}
{111} and {100}
Crystal habit
{111} and {110}
crystals twinned on {111}
irregular blocky forms
Twinning growth twinning on {111}
TABLE - 3
4366,
4695 (undoped);
Hardness
[HK] 4572 (Be-doped)
4500 on {111} in <110>
~ 4500
Note: 1.The accepted hardness value is 4500 HK (about half that of diamond).
1.4.3. THERMAL PROPERTIES:
Cubic boron nitride is extremely stable in air, nitrogen or vacuum -
temperatures ca. 1400 - 1550 °C have to be exceeded before any change in
stability occurs. This is in marked contrast to diamond which starts to form a
graphite surface film at temperatures ca. 650 °C in the presence of oxygen.
The specific heat values are approximately twice that for diamond,
whilst the thermal conductivity value is much lower than that of diamond. The
values for thermal expansion between 430 °C and 1160 °C are slightly higher
than those for diamond.
TABLE - 4
Specific heat 12.55 at 300 K
[J/(mol K)] 25.1 at 600 K
4.80 at 430 °C
Linear thermal
4.30 at 700 °C
expansion
−6
5.60 at 900 °C
[10 /K]
5.80 at 1160 °C
TABLE - 5
Heat of formation −251 value for the graphitic layer lattice form at 298 K
[kJ mole−1] −266 calculated value for CBN
RESISTIVITY[Ω Cm]:
p-type (Be-doped)
102– 104 0.19 - 0.23 eV (activation energy for conduction)
DIELECTRIC CONSTANT:
ε0= 7.1 ε∞ = 4.5
1.4.6. CHEMICAL REACTIVITY:
Study of chemical properties of materials is necessary because most of
the engineering materials, when they come in contact with other substances
with which they can react, tend to suffer from deterioration.
TABLE - 6
1.5. APPLICATIONS:
Typically they are used for hard ferrous materials (Rc 45 or harder) that
are difficult to machine with carbide or ceramic or that require time consuming
grinding operations.
TABLE - 7
1.7. ADVANTAGES:
ROUGHING :
• Efficient machining of pearlitic gray cast iron
• Turning hard facing alloys
• Machining of powder metal alloys
• Turning of superalloys
FINISHING :
• High speed finish machining of hardened steel (>45 Rc)
• Suitable for continuous machining of hardened steels
• Replace grinding operations.
1.8. DIFFERENT OPERATIONS USING CBN:
FIGURE - 1
FIGURE - 2
1.11. RELATIVE STRENGTH OF THREE REPRESENTATIVE CBN GRADES AFTER
HEAT TREATMENT AT DIFFERENT TEMPERATURES:
FIGURE - 3
FIGURE - 4
1.13. DIFFERENT GRADES OF CBN:
H.C. Starck Grade A 01 Boron Nitride, BN
H.C. Starck Grade B 50 Boron Nitride, BN
H.C. Starck Grade B 100 Boron Nitride, BN
H.C. Starck Grade C Boron Nitride, BN
H.C. Starck Grade F 15 Boron Nitride, BN
This results in a material with the hardness, abrasive resistance and high
thermal conductivity of diamond with the toughness of hard metal. Using the
hard metal substrate the PCD blank is brazed to a carrier, either steel or hard
metal, and machined by grinding or E.D.M to produce the cutting edge.
When compared to other cutting tool materials, there are three main
reasons for using PCD tools:-
Increased tool life results in reduced tool cost per component and less
idle machine time.
Increasing cutting speed improves productivity through reduced cycle
times.
Grinding and other less productive machining methods can be replaced
by PCD milling and turning.
The forces required to grind PCD with Diamond are extremely high. This
means that it has been very difficult to produce cutting tool inserts accurately
enough to work properly in the fixed pocket milling cutters commonly
available. Cutters with adjustable pockets for the inserts were developed, but
these require care and patience to set up and are expensive to buy and repair.
Poly – Crystalline Diamonds exist both in nature and also can be
manufactured artificially using man-made diamond particles.
TABLE - 9
CHEMICAL FORMULA C
STREAK WHITE
2.2.1. PROPERTIES:
Mineral grains included within diamonds have been studied extensively for
clues to diamond origin:
2.3.1. FABRICATION:
2.3.2. PROPERTIES:
TABLE - 10
1. It can be inserted into PCD cutting tools, PCD drilling bits/core bits,
PCD wire drawing dies, reamers and other wear resistant components.
4. These diamond bits are also used on brass, copper, carbide and
bronze in applications including turning, boring, profiling, grooving, milling and
hole making.
TSP/PCD mining and oil drilling bits are best suited for more abrasive or
broken formations. PCD drill bits are suitable for drilling in soft rocks with
hardness below 7 degrees such as lime rock, marble, shale, etc., and in
medium to hard rocks with coarse grains such as sedimentary rock.
FIGURE - 5
2.6. DIFFERENT SIZES OF PCD IN USED VARIOUS APPLICATIONS:
TABLE - 11
2.7. PHYSICAL PROPERTIES OF SOME PCD PRODUCTS:
TABLE - 11
2.9. DISADVANTAGES:
2. http://www.cutting-
tool.americanmachinist.com/guiEdits/Content/bdeee15/bdeee15_1.aspx
3. http://www.meister-abrasives.ch/en/technology/abrasive_materials/cbn
4. http://www.china-superabrasives.com/Cubic_Boron_Nitride.htm
5. http://www.wwsuperabrasives.com/Cubic_Boron_Nitride.html
6. http://china-superabrasives.com/PCD_polycrystalline_diamond.htm
7. http://www.xinruitools.com/sl_001.html
8.http://pubs.acs.org/action/doSearch?action=search&searchText=cubic+boro
n+nitride&qsSearchArea=searchText&type=within&publication=40026050
9. http://drengus.com/featured/what-is-pcd/