Increasing the reliability of a bladed tool made from synthetic polycrystalline diamonds

The results of static and dynamic 3D modeling of the cutting process with a blade tool made of synthetic polycrystalline diamonds (PCD) are presented. Theoretical studies using the DEFORM-3D and COSMOSWorks software packages made it possible to study the influence of the bond's properties, the presence of metal phase inclusions in the structure of synthetic diamonds (their number, composition and size) and the temperature in the cutting area on the stress-strain state (SSS) of the studied “cutting edge – metal phase” system. The level of SSS was estimated by determining the maximum values of equivalent stresses in the places of accumulation of metal inclusions, the thermal expansion coefficient of which is much higher than that of diamond. A method for sharpening cutters with PCD blades is proposed to ensure reliability at the manufacturing stage (sharpening). [Display omitted] •Static and dynamic 3D models of machining synthetic polycrystalline diamond tools are presented.•The influence of the bond's properties and the metal phase inclusions in the diamond tool are studied.•The temperature in the cutting area is investigated in connection to the stress-strain state of the cutting edge.•A method for sharpening cutters is proposed to ensure reliability at the manufacturing stage.