Single crystal diamond (Natural and Synthetic) is used to machine non-ferrous metals, plastics
and infrared crystals. Being the hardest material on earth, it’s unique crystalline structure
makes it possible to achieve near perfect cutting edges that are critical for machining optical
surfaces.
Diamond is a cubic crystal, and its shear strength varies by a factor of 100 between its
hardest and softest planes. So it is crucial that each diamond tool has the proper crystal
orientation in order to give the longest tool life.
Although diamond is extremely hard, it is also quite brittle. Tools should be handled with
extreme care, and nothing should come in contact with the edge other than the workpiece.
TOOL CLEANING
When cleaning the tool (on or off the machine) use isopropyl alcohol or acetoneand a lint
free cloth or a Q-tip. Always wipe along the front of clearance angle along the cutting edge.
Paint brushes and un-filtered compressed air can hold particles that can cause damage,
so are not recommended. Never drag anything from the top of the diamond over the cutting
edge, as this may cause a chip-out.
CONDITION OF A NEW K&Y DIAMOND TOOL
Your new K&Y Diamond tool is manufactured with care by highly skilled tooling engineers
and technicians. Our proprietary processes combined with ultra-precision machine tools
and state-of- the-art metrology assures the highest quality tools at a competitive price.
Depending on customer requirements, the peak-to-valley variation from a perfect arc (waviness)
is between .01 micron and 2 microns as measured by profilometer and/or video microscope.
The cutting edge is chip and defect free at 800X. If required, we can offer inspection using
our scanning electron microscope up to 150,000 magnification!
TOOL WEAR AND WHEN TO REPAIR
Diamond tool wear is most often a micro-fracturing of cutting edge. This shows up in part as
increased surface roughness, varying power, or surface irregularity.
Wear rate is caused by several variables including:
• Material being cut
• Impurities
• Temperature
Cutting parameters
1. Coolant media and flow
Water based is generally better than oil or OMS (odorless mineral spirits) for heat removal.
Oil based has more lubricity. Higher flow creates better heat transfer.
2. Depth of cut and Feed-rate
There is an optimum depth of cut and feed rate to get the most life out of a tool, but this
needs to be balanced with the desired rate of production.
3. Stiffness and dampening
Keep tool overhang as short as possible. Keep fixtures small and close to the spindle.
Tools that are damaged can be repaired or ‘relapped’ by K&Y Diamond at a fraction of new
tool cost. The relap process consists of removing a minimal amount of material from the rake
face (top) until the new plane is just below the previously damaged area. After lapping, the
tool is re-certified and re-labeled showing measured radius, cutting height and waviness.
Typical turnaround time for this service is 1-2 business days. A tool can typically be relapped
10-20 times depending on wear depths. If tool has more severe damage that goes further
down the front clearance, it may be best to “recone” the diamond. This includes polishing
the front clearance angle and then lapping the top. Depending on the diamond thickness, it
can be an economical alternative to buying a new tool. K&Y Diamond’s technical team
is available to answer any questions you may have and fulfill all of your diamond tooling
needs. Please do not hesitate to contact us with any questions!
