A Study on Fabrication of PCD Boring Tool Body based on Metal 3D Printing Technology

The future mobility industry is increasingly utilizing advanced tools for cutting and machining lightweight parts to enhance the fuel efficiency of automotive engines. Machining companies are turning to polycrystalline diamond (PCD) tools to boost productivity in the production of these lightweight components. PCD tools provide exceptional machining performance and a long service life, making them ideal for high-mix, low-volume production, which often involves customized requirements for various materials. To further improve efficiency, this study explores the application of metal 3D printing technology in the manufacturing of PCD tools. This technology allows for the creation of PCD tools with superior cutting performance and wear resistance, tailored for high-speed machining of lightweight materials, including complex shapes. Thus, research into this area is essential. In this study, we manufactured boring tools by brazing PCD tips onto three different laminated structures created using Fused Deposition Modeling (FDM), a method within metal 3D printing technologies. We then evaluated the fabricated boring tools through comparative machining experiments against existing sintered PCD boring tools. The results indicated that the 3D-printed solid tools demonstrated no significant differences in machining accuracy or surface quality compared to the conventional tools.