Our production line is mainly divided into the following five core sectors:
I. Raw material preparation and pressing plate: the cornerstone from powder to "roughcast"
Process: Utilizing advanced "spray drying" technology, ultra-fine tungsten carbide powder, cobalt powder, and other raw materials are mixed with paraffin in a specific formula to form a granular mixture with excellent fluidity.
Equipment: Fully automatic powder compaction machine.
Process:
The mixture is filled into precision molds through an automatic feeding system.
Under the pressure of tens of tons to hundreds of tons, it is pressed into the preliminary shape (green) of the drill bit.
Quality Control Points: The automated weighing system ensures the consistency of the weight of each green compact, serving as the first critical step in controlling the density and dimensional stability of the final product.
II. Sintering and Forming Section: The "High-Temperature Quenching" that Gives Life
Process: This is the core of cemented carbide production. The green compacts are placed in a vacuum/low-pressure sintering furnace and sintered at high temperatures, close to 1400°C.
Process: During this process, the paraffin is completely discharged, the cobalt powder melts and binds the hard tungsten carbide particles tightly together, resulting in significant shrinkage (about 18%), and ultimately obtaining a high-hardness, high-density drill bit matrix.
Intelligent: Fully computerized temperature control, real-time monitoring of temperature and pressure curves inside the furnace, ensuring that the physical properties (hardness, density, bending strength) of each batch of products are optimal and consistent.
III. Precision Grinding Sector: "Meticulously Crafted" with Micron-Level Precision
This is the core link to determine the geometric accuracy and cutting performance of the drill bit. We use the world's top five-axis CNC tool grinding machine.
Grinding process:
Cylindrical grinding: First, ensure the roundness and dimensional accuracy of the drill shank to ensure stable clamping.
Slot grinding (core): Using a diamond grinding wheel, the drill point angle (118°, 140°, etc.), helical chip flute, edge band, and clearance angle are precisely ground in a single setup. This is the "soul" of the drill bit.
Grinding of Inner Cooling Holes (Key Technology): For inner cooling drill bits, a special process is used to grind out inner cooling holes with an extremely small diameter and high concentricity.
Online detection: Equipped with online measuring probes during grinding, real-time compensation for wheel wear ensures the stability of machining dimensions.
IV. Ultra-precision processing and coating plate: wearing the "god of war armor"
1. Blade treatment:
Process: The cutting edges are passivated (T-Edge) or sharpened using specialized brushes or grinding equipment. This eliminates micro-chipping, significantly enhances the edge strength and resistance to chipping, and prolongs the tool's lifespan.
2. Surface coating:
Equipment: Fully automated PVD (Physical Vapor Deposition) and CVD coating equipment.
Process: The cleaned drill bit is loaded into a coating furnace, where nanoscale coating materials such as TiAlN and AlCrN are uniformly deposited on the surface of the drill bit through arc or sputtering techniques in a high-temperature vacuum environment.
Effect: The coating is like a hard "armor" for the drill bit, greatly improving its wear resistance and heat resistance.
V. Quality Inspection and Packaging Section: The "Ultimate Test" Before Delivery
100% full inspection:
Geometric Dimensions: Utilizing high-precision laser measuring instruments and optical imaging measuring instruments, we conduct a 100% inspection of critical dimensions such as drill diameter, edge runout, and drill point symmetry.
Appearance defects: An automated visual inspection system detects whether there are flaws, cracks, etc. on the coating surface.
Random inspection:
Performance testing: Actual cutting tests are conducted on each batch of products on a standardized machining center to verify their drilling accuracy, hole wall quality, and lifespan.
Smart Packaging and Traceability:
Qualified products are packaged through automatic packaging lines.
Each drill bit or package has a unique traceability code that can be traced back to the production batch, machine number, operator, and raw material batch, enabling full lifecycle quality management.
Summary of core advantages of production line
High automation: From feeding, processing to testing, minimize human intervention to ensure stability and consistency.
Data informatization: Production data is uploaded to MES (Manufacturing Execution System) in real time, enabling transparency and traceability analysis of the production process.
Integrated Process: We manage the entire process from powder production to finished product, ensuring seamless connection of process parameters and quality assurance from the source.
Flexible manufacturing capability: CNC grinding machines can quickly switch programs and flexibly respond to production needs for small batches, multiple varieties, and non-standard customization.
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