Electroplated diamond reamers, also known as diamond honing reamers or honing rods, have no cutting teeth and mainly rely on "grinding" to complete the machining. It is a new process formed by combining ordinary honing and conventional reaming processes.
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I.Materials and Classification of Reamers
1. Materials
According to the material of the workpiece to be machined, the material of the honing reamer can be selected as diamond or CBN.
Diamond honing reamers are mainly used for machining glass fiber reinforced plastics, cemented carbides, superalloys, etc.
CBN reamers are mainly used for machining quenched steel, chilled cast iron, wear resistant alloy steels, etc.
2. Classification
According to the machining process and application of the reamer, it can be divided into fixed and adjustable reamers.
Fixed diamond honing reamers: The diameter is fixed and cannot be reused after wear. It is suitable for blind - hole machining. The front guide, reamer body, and rear guide are of an integrated structure, which is simple to manufacture and suitable for mass production.
Adjustable diamond honing reamers: After wear, the cutter sleeve of the reamer can be adjusted. The diameter can be restored by fine - tuning the cutter sleeve, thus realizing reuse and reducing costs. It is suitable for through - hole machining.
In use, the adjustable diamond reamer is used for rough reaming, and the fixed diamond reamer is used for fine reaming to improve machining efficiency and accuracy.
II. Usage Method of Reamers
Install the honing and reaming rod into the corresponding honing machine. From the first axis to the last axis, the outer diameter of the honing sleeve abrasive increases successively, and the abrasive grain size also changes from coarse to fine. After the inner hole of the workpiece is honed and reamed successively from the first axis to the last axis of the honing and reaming rod, the aperture gradually increases, and the roughness gradually decreases. After passing through the last cutter, the part can reach the required size, roughness, and form-position tolerance. The key to whether the reaming process can achieve the expected accuracy is to select scientific honing and reaming tools and honing and reaming processes.
III. Selection of Machining Allowance
Generally, it should not exceed 1/3 - 1/4 of the particle size of the abrasive itself. Otherwise, the diamond reamer will be stuck in the workpiece hole due to excessive chip accumulation, which will reduce the service life of the tool.
For diamond honing reamers with a grain size of 80/100 - 100/120, the machining allowance should be controlled between 0.02mm - 0.04mm.
For diamond reamers with a grain size of 170/200 - 230/270, the machining allowance should be controlled between 0.015mm - 0.005mm.
For diamond reamers with a fine grain size of 325/400, the machining allowance should be controlled between 0.005mm - 0.01mm.
IV. Selection of Cutting Fluid
When using HDK electroplated diamond reamers to ream cast - iron holes, a mixed oil of 80%
kerosene and 20% sulfurized oil or mechanical oil can be used as the cooling cutting fluid, and all
kerosene can also be used.
When using HDK electroplated diamond reamers to ream steel parts, a mixture of 70% kerosene and 30% sulfurized oil can be used.
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