Development of an optimal lapping process for polycrystalline diamond compact (PDC)
This paper presents the results of a comprehensive study regarding the lapping of polycrystalline diamond compact (PDC). The primary goal of this study was to maximize the material removal rate (MRR) of the lapping process. A kinematic model was first developed to provide a fundamental understanding on the motion trajectories of a PDC specimen on the lapping plate. It followed with the development of a lapping vehicle suitable for the suspension of larger diamond grits that were needed for the lapping of PDC cutters. Experiments were then conducted to evaluate the effects of various combinations of lapping parameters on the MRR. These parameters include lapping pressure, lapping speed, diamond concentration, and diamond dispensing rate. After an efficient lapping process was identified, the optimal layout of PDC samples on the specimen holder became the study focus and various layout patterns have been investigated. To assist in the determination of the optimal lapping pressure, spent diamond abrasives were reclaimed and their grit size distributions were analyzed.
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