Significantly reduce setup time due to component degradation! We provide support from current situation analysis and issue identification to solution proposals, component supply, and effect measurement.
【Independently Developed PCD Material】 MDI has developed a unique material in collaboration with material manufacturers while pursuing the durability of glass cutting tools. The diamond powder has an ultra-fine particle size of less than 1 µm, and compared to conventional PCD materials, it possesses the following characteristics: - Improved wear resistance and overcoming brittleness - No occurrence of edge chipping or chipping specific to PCD This allows for excellent machinability and enables delicate and high-precision processing. 【PCD High-Precision Processing Know-How】 Leveraging its high hardness, it is generally used for cutting and grinding tools for hard alloys and brittle materials. At MDI, we have accumulated years of experience in manufacturing PCD tools for cutting brittle materials, including glass, and have developed high-precision processing and quality inspection techniques at the micrometer level.
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basic information
■What is PCD? Polycrystalline Diamond (PCD) is also known as "sintered diamond." As the name suggests, it is a type of artificial diamond that is made by mixing diamond powder from single crystals with a binder such as cobalt and then sintering it in a high-temperature, high-pressure furnace to create a polycrystalline structure. ■Characteristics of General PCD Materials 【〇: Excellent strength and wear resistance】 【×: Potential for damage from impacts due to drops or contact】 Compared to superhard materials, PCD has the above characteristics and can be expected to have a lifespan more than 10 times longer, but it also has the disadvantage of limited shape due to its difficult machinability. *Example of PCD performance (compared to superhard materials) Hardness Hv: About 6 times, Wear and chipping resistance: About 25 times.
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Applications/Examples of results
[Case Studies of Problem Discovery and Resolution] ■ Case 1 (Major Precision Parts Manufacturer) In response to quality deterioration due to the aging of cutting edges in the precision parts cutting process, we conducted a root cause analysis of the quality decline and created an improvement proposal report, which was implemented. This led to an improvement in the quality and stabilization of the customer's products, achieving optimization of the customer's production process. ■ Case 2 (Major Parts Processing Manufacturer) For customers using carbide material mold punch components, we proposed PCD material components and improved processing methods. This resulted in achieving a continuous production quantity over ten times that of before the proposal! We stabilized product quality and significantly reduced the time for regrinding and setup change operations. ■ Case 3 (Equipment Manufacturer) For expensive unit components that were being used as disposable within equipment parts, we leveraged our proposal capabilities and processing technology to suggest a partial exchange system. This simplified the exchange process and reduced component costs, contributing to increased production numbers and reduced manufacturing costs.
Detailed information
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※Example of punching with PCD punches and dies Feature 1: Stability of Initial Quality Compared to hard materials that take time to stabilize in quality, PCD materials maintain stable quality from the beginning.
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*Example of punching with PCD punches and dies* Feature 2: Maintaining consistent quality Compared to ultra-hard materials where clearance changes with each regrinding, our robust edges do not wear or chip, ensuring that clearance remains constant.
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※From examples of punching with PCD punches and dies Feature 3: Component lifespan 6 times longer + α Compared to carbide materials that required regrinding every 6 million shots, we achieved over 6 times the continuous shots.
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*From examples of punching with PCD-made punches and dies* Feature 4: Significant reduction in regrinding and parts replacement work By using PCD material, the regrinding and replacement work that occurred with carbide materials has been reduced to less than one-twentieth. (This is just an example and does not guarantee all shapes.)
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Company information
Samsung Diamond Industrial is a manufacturer of processing equipment that provides optimal process conditions using original cutting edges and laser oscillators for processing methods such as scribing, breaking, drilling, and patterning, along with automated devices that achieve high productivity. Since its establishment in 1935, the company has utilized its "high-quality cutting technology for various types of glass" to offer processing processes, equipment, and tools that can handle "all kinds of hard and brittle materials, as well as multilayer structures that include metals and organic materials." With solutions backed by theory and proven results, we aim to be a reliable "one-and-only partner" for our customers. Please feel free to contact us.
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