The Material Composition and Detailed Introduction of Composite Drill Bits

Composite drill bits, as a high-performance cutting tool, have been widely used in various industrial fields due to their unique material composition and excellent cutting performance. This article will delve into the material composition of composite drill bits, elaborate on their advantages, and introduce some well-known brands and models in detail.

Material Composition of Composite Drill Bits

Composite drill bits are typically composed of two main parts: the cutting layer and the substrate. The cutting layer is the core part of the drill bit that directly contacts the workpiece and performs the cutting operation, while the substrate provides support and rigidity to the cutting layer.

Cutting Layer Material

The cutting layer of composite drill bits is usually made of polycrystalline diamond (PCD) or polycrystalline cubic boron nitride (PCBN). These materials are known for their extremely high hardness, wear resistance, and thermal conductivity, making them ideal for cutting hard and abrasive materials.

1. Polycrystalline Diamond (PCD)
   PCD is a composite material formed by sintering diamond particles and a metal binder under high temperature and pressure. It combines the high hardness and wear resistance of diamond with the toughness and processability of the metal binder. PCD cutting layers are particularly suitable for cutting non-ferrous metals, non-metallic materials, and composite materials, such as aluminum alloys, copper alloys, plastics, and carbon fiber-reinforced composites.
2. Polycrystalline Cubic Boron Nitride (PCBN)
   PCBN is another high-performance cutting material, second only to diamond in hardness. It is formed by sintering cubic boron nitride particles and a metal or ceramic binder. PCBN cutting layers exhibit excellent wear resistance and thermal stability, making them ideal for cutting ferrous metals, such as cast iron, hardened steel, and high-speed steel.

Substrate Material

The substrate of composite drill bits is usually made of hard alloy, also known as cemented carbide. Hard alloy is a composite material composed of tungsten carbide (WC) particles and a metal binder, such as cobalt (Co). It provides the necessary rigidity and support to the cutting layer, ensuring that the drill bit can withstand high cutting forces and vibrations during the cutting process.

Advantages of Composite Drill Bits

Composite drill bits offer several significant advantages over traditional drill bits, making them a preferred choice in many industrial applications.

1. High Hardness and Wear Resistance
   The use of PCD or PCBN cutting layers gives composite drill bits extremely high hardness and wear resistance. This allows them to maintain their cutting edge sharpness for a longer period, reducing the frequency of tool changes and improving production efficiency.
2. Excellent Thermal Conductivity
   Both PCD and PCBN have high thermal conductivity, which helps to dissipate heat generated during the cutting process quickly. This reduces the risk of thermal damage to the workpiece and the drill bit, extending their service life.
3. High Precision and Surface Quality
   Composite drill bits can achieve high cutting precision and surface quality due to their sharp cutting edges and stable cutting performance. This is particularly important in applications where high precision and surface finish are required, such as in the aerospace and automotive industries.
4. Wide Range of Applications
   Composite drill bits can be used to cut a wide range of materials, including non-ferrous metals, non-metallic materials, composite materials, and ferrous metals. This versatility makes them suitable for various industrial applications, from automotive manufacturing to aerospace engineering.

Well-Known Brands and Models of Composite Drill Bits

There are several well-known brands in the market that offer high-quality composite drill bits. Below are some of the most popular brands and their representative models:

1. Kennametal

Kennametal is a global leader in the manufacturing of cutting tools and industrial supplies. Their composite drill bits are known for their high quality and excellent performance.

Model: KCP25
The Kennametal KCP25 is a PCD-tipped drill bit designed for drilling aluminum alloys and other non-ferrous metals. It features a unique flute design that improves chip evacuation and reduces cutting forces, resulting in higher productivity and longer tool life. The KCP25 is available in various diameters and lengths to suit different drilling requirements.

Model: KCBN30
The Kennametal KCBN30 is a PCBN-tipped drill bit designed for drilling hardened steels and other ferrous metals. It exhibits excellent wear resistance and thermal stability, allowing it to maintain its cutting edge sharpness even under high-temperature cutting conditions. The KCBN30 is ideal for applications where high precision and surface finish are required.

2. Sandvik Coromant

Sandvik Coromant is another leading manufacturer of cutting tools and metalworking solutions. Their composite drill bits are widely used in various industries due to their high performance and reliability.

Model: CoroDrill 860-PM
The Sandvik Coromant CoroDrill 860-PM is a PCD-tipped drill bit designed for drilling composite materials, such as carbon fiber-reinforced plastics (CFRP). It features a special edge preparation that reduces delamination and improves hole quality. The CoroDrill 860-PM is available in a wide range of diameters and lengths, making it suitable for various drilling applications.

Model: CoroDrill 870-CBN
The Sandvik Coromant CoroDrill 870-CBN is a PCBN-tipped drill bit designed for drilling hardened steels and other ferrous metals. It offers excellent wear resistance and thermal stability, allowing it to perform well even under challenging cutting conditions. The CoroDrill 870-CBN is ideal for high-precision drilling applications in the automotive and aerospace industries.

3. Mitsubishi Materials

Mitsubishi Materials is a Japanese company that specializes in the manufacturing of cutting tools and advanced materials. Their composite drill bits are known for their high quality and innovative designs.

Model: MPX Series
The Mitsubishi Materials MPX series is a line of PCD-tipped drill bits designed for drilling aluminum alloys and other non-ferrous metals. These drill bits feature a unique flute geometry that improves chip evacuation and reduces cutting forces, resulting in higher productivity and longer tool life. The MPX series is available in various diameters and lengths to suit different drilling requirements.

Model: MCBN Series
The Mitsubishi Materials MCBN series is a line of PCBN-tipped drill bits designed for drilling hardened steels and other ferrous metals. These drill bits exhibit excellent wear resistance and thermal stability, allowing them to maintain their cutting edge sharpness even under high-temperature cutting conditions. The MCBN series is ideal for high-precision drilling applications in the automotive and aerospace industries.

4. ISCAR

ISCAR is an Israeli company that specializes in the manufacturing of cutting tools and metalworking solutions. Their composite drill bits are widely used in various industries due to their high performance and innovative designs.

Model: SUMOCHAM
The ISCAR SUMOCHAM is a PCD-tipped drill bit designed for drilling composite materials, such as CFRP. It features a unique drill head design that reduces delamination and improves hole quality. The SUMOCHAM is available in various diameters and lengths, making it suitable for various drilling applications in the aerospace and automotive industries.

Model: CHAMDRILL-CBN
The ISCAR CHAMDRILL-CBN is a PCBN-tipped drill bit designed for drilling hardened steels and other ferrous metals. It offers excellent wear resistance and thermal stability, allowing it to perform well even under challenging cutting conditions. The CHAMDRILL-CBN is ideal for high-precision drilling applications in the mold and die industry.

Conclusion

Composite drill bits, with their unique material composition and excellent cutting performance, have become an indispensable tool in various industrial applications. The use of PCD or PCBN cutting layers, combined with hard alloy substrates, gives composite drill bits high hardness, wear resistance, thermal conductivity, and precision. Well-known brands such as Kennametal, Sandvik Coromant, Mitsubishi Materials, and ISCAR offer a wide range of composite drill bits with different models and specifications to suit various drilling requirements. Whether it’s drilling non-ferrous metals, non-metallic materials, composite materials, or ferrous metals, there’s a composite drill bit that can meet the needs of the application. As technology continues to advance, composite drill bits are expected to play an even more important role in the future of industrial manufacturing.