Application Background
With advances in material science, an increasing number of precision components are made from advanced hard-brittle materials such as ceramics, silicon carbide (SiC), alumina (Al₂O₃), silicon nitride (Si₃N₄), and zirconia (ZrO₂).
While these materials offer outstanding hardness, heat resistance, and wear resistance, they also significantly raise machining difficulty. As a result, many industries are shifting from conventional cutting tools to diamond and CBN solutions using electroplated and metal-bond systems to balance accuracy, efficiency, and tool life.
Machining Challenges
- Excessive hardness: Conventional carbide tools wear rapidly or may not cut effectively.
- Brittle fracture: Edge chipping and breakage occur easily, making it difficult to maintain both yield and dimensional stability.
- Low thermal conductivity: Local heat buildup can cause thermal cracks or micro-cracks, increasing downstream reliability risks.
Our Solution
We develop electroplated diamond/CBN tools and metal-bond diamond tools specifically for demanding processes on hard-brittle materials, including ID machining, hole making, profiling/finishing, and thread machining (helical thread forming/refinement).
- Electroplated Bond: Highly exposed abrasive grains deliver extremely high cutting action. Ideal for small diameters and high-precision machining—especially suitable for deep features, complex profiles, or micro-machining requiring high removal rates.
- Metal Bond: Higher bond strength and excellent wear resistance. Well suited for long, stable machining cycles and larger-area material removal, enabling more consistent size control and surface quality.
Products / Functions
- Electroplated Diamond Grinding Pins / Electroplated CBN Grinding Pins: Deep holes, micro-hole drilling, ID finishing, contour finishing, and helical machining inside tap-holes, etc.
- Metal-Bond Diamond Tools: For long-cycle machining, high surface-finish requirements, and process stages requiring tighter dimensional consistency.
- CBN Tools: Provide stable performance and durability for high-hardness steels (e.g., HRC 50 and above)
Bonding Features
Electroplated
- Extremely high cutting performance for fast removal of hard materials.
- Flexible tool geometry for small diameters, long cutting lengths, and special profiles.
- Suitable for one-time high-efficiency machining or high-precision correction/finishing.
Metal Bond
- Long tool life and excellent wear resistance for stable, long-cycle machining.
- Smoother cutting behavior, beneficial for improved surface roughness (Ra).
- Ideal for production machining or processes requiring high dimensional consistency.
Applicable Workpiece Materials
- Ceramics (Al₂O₃, Si₃N₄, SiC, ZrO₂)
- Optical glass / quartz
- Cemented carbide (WC-Co)
- Semiconductor substrates and related hard-brittle components
- High-hardness tool steels and heat-treated steels (CBN recommended)
Recommended Machining Parameters
The following are conservative starting values intended to help customers establish a workable baseline. Final parameters must be validated and fine-tuned based on material, machine rigidity, runout, tool overhang, coolant delivery, and debris evacuation.
Coolant recommendation: water-soluble grinding fluid (solution type) or clean water cooling. Avoid dry machining to reduce overheating, chipping, and thermal cracking risks.
Use Case 1: Helical Thread Grinding Parameters
(M3 / M6 / M8)
Electroplated Thread Tool (diamond/CBN selected by material)
Method: Helical toolpath inside a tap-hole to form/refine the thread.
| Thread |
Recommended Speed n (rpm) | Recommended Feed f (mm/min) |
Recommended Infeed ap (mm/pass) | Notes |
| M3 |
6,000 |
60–100 |
0.015–0.02 |
Smaller threads are more sensitive to vibration and chipping—prioritize stability |
| M6 |
6,000 | 100–150 |
0.02 |
Baseline reference aligned to published catalog conditions |
| M8 |
6,000 |
120–180 |
0.02 | Larger pitch may allow higher feed, depending on machine rigidity |
Metal-Bond Thread Tool (diamond/CBN selected by material)
Method: Helical toolpath inside a tap-hole to form/refine the thread.
| Thread |
Recommended Speed n (rpm) | Recommended Feed f (mm/min) |
Recommended Infeed ap (mm/pass)
|
| M3 |
6,000 |
45–85 |
0.01–0.015 |
| M6 |
6,000 |
70–135 |
0.01–0.015 |
| M8 |
6,000 |
85–160 |
0.01–0.015 |
Use Case 2: Abrasive Hole-Making Parameters (Ø1.5 / Ø3 / Ø6)
Electroplated Grinding Pins / Tools
Method: Use pecking cycles to improve debris evacuation and heat control, with continuous coolant supply.
| Hole Ø |
Recommended Speed n (rpm) | Recommended Axial Feed f (mm/min) |
Peck (per step) |
| Ø1.5 |
18,000–24,000 |
0.5–1.2 |
0.2–0.4 mm |
| Ø3.0 |
9,000–12,000 |
0.8–1.8 |
0.4–0.8 mm |
| Ø6.0 |
4,500–6,000 |
1.2–3.0 |
0.8–1.5 mm |
Note: If the spindle cannot reach the recommended speed, run at the machine’s maximum available RPM and reduce feed accordingly. Smaller holes are more sensitive to runout control and coMetal-Bond Grinding Pins / Tools
Metal-Bond Grinding Pins / Tools
Method: Start more conservatively than electroplated, then gradually increase efficiency.
- Speed: same starting range as electroplated
- Feed: start at 70–90% of electroplated values
- Pecking: use more frequent pecking (especially for deep holes or low-thermal-conductivity materials)
| Hole Ø |
Recommended Speed n (rpm) | Recommended Axial Feed f (mm/min) |
Peck (per step) |
| Ø1.5 |
18,000–24,000 |
0.4–1.0 |
0.2–0.4 mm |
| Ø3.0 |
9,000–12,000 |
0.6–1.6 |
0.4–0.8 mm |
| Ø6.0 |
4,500–6,000 |
1.0–2.5 |
0.8–1.5 mm |
Operating Notes & Precautions
- Cooling is mandatory: Use water or water-soluble grinding fluid to prevent tool overheating and workpiece thermal cracking/chipping.
- Avoid excessive pressure: Overloading may cause grain pull-out, edge chipping, damaged hole entry, or dimensional deviation.
- Use pecking for deep holes: Improves debris evacuation and heat dissipation, significantly extending tool life.
- Alignment and fixturing: Ensure spindle/workpiece concentricity to reduce bore deviation, cracks, and breakage risks.
- Respect Max RPM: Do not exceed the tool’s rated maximum speed and the spindle’s allowable limit; validate based on overhang and clamping rigidity.