Nano-range surface finish on laser machining PCBN material

Testing conducted at Rollomatic’s showroom facility in Mundelein, Illinois – without sacrificing feed rates or cycle times – produced a surface finish of Ra 48nm (0.048µm) on a primary relief of a profile insert in polycrystalline cubic boron nitride (PCBN) material. Performed on the LaserSmart LS510 cutting and ablation machine with five interpolating CNC axes, the process ensured integrity of the edge quality was fully maintained. A super-mirror finish is generally known to be around 100nm which Rollomatic was able to cut in half.

Verification and measuring were done by a Bruker-Alicona EdgeMaster optical 3-dimensional metrology unit.

The LaserSmart LS510 produces a sharp corner radius in polycrystalline diamond/cubic boron nitride (PCD/CBN) with a maximum radius on the cutting edge below 0.5µm. A defined radius of 3µm, 6µm, and 9µm can be consistently produced. In addition to round-shaft tools, the machine can also accommodate HSK63 shanks.

LaserSmart LS510 delivers:

• Up to 4x faster feed rates with identical edge, surface quality
• 3D machining of drill points, end mill cutting geometries
• Processes to sharpen the cutting edge of CVD, thick-film diamond coated cutting tools
• Fine laser cutting for superfine cutting edge, pristine surface finish
• Linear motion technology on all linear, rotary axes for highly accurate trajectories for complex cutting paths
• Laser ablation to optimize tool geometries
• Manufacturing chip form geometries in PCD using ablation as a cost- effective, powerful alternative to existing, complicated, expensive conventional methods