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semiconductor. Again, it is electrically neutral. It is interesting to note that electron holes are mobile in the same way that free electrons are. As such, they are considered charge carriers. In most explanations, electron holes are said to carry a positive charge. Holes and free electrons occur naturally in the silicon lattice, as well as because of the added impurities. The free electrons and holes created by the dopants outnumber these natural ones, and are known as the majority carriers. They carry the majority of the charge. Any natural free electrons and holes in the lattice are the minority carriers and provide a small background leakage current. Even though Fig. 12-3 through 12-5 have been simpli ed down from the complex model in Fig. 12-1, it is still hard to see the di erences at a glance. We don t need to see the silicon as an atom at all. We can condense the picture down to the pure electron grid, as shown in Fig. 12-6. And even this



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Tool Materials for Precision Machining be a composite material that combines the high thermal conductivity of diamond with the brazeabiity of WC Both the PCD layer, by virtue of its cobalt content, and the WC substrate are electrically conducting This allows machining by wire cut EDM as shown in Figure 228 [35] The microstructure of a PCD of grade 010 is shown in Figure 229 [36] This new cutting tool material has the properties of carbonados This sintered single diamond particle consists of millions of tiny, randomly oriented crystals fused together Fig 228: PCD inserts produced by EDM The extremely high hardness of these crystals machining provides wear resistance, and the random orientation of the cleavage planes provides strength and toughness It is capable of machining tough, abrasive non-ferrous metals, plastics, ceramics and glass Polycrystalline diamond tools are used for making drills, end mills and other milling cutters as well as for making turning tools since they give less burn, enabling cutting speeds and feeds to be increased





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Fig. 12-7.

245 Single-crystal Diamond (SPSCD)

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Single point single-crystal diamonds are used for special applications such as machining copper-front high-precision optical mirrors Ultraprecision diamond turning requires large single-crystal diamonds preferably of the quality used for making gems, found only in nature The performance of diamond tool depends on the quality of the Fig 229: Microstructure of a diamond, the crystal orientation and the cutting edge finish Because grade 010 PCD [36] diamonds are brittle, their tool shape and sharpness are important When producing tools, it is very important that the cutting edge is as sharp and as smooth as possible Low and negative rake angles (large included angles) are normally used to provide a strong cutting edge The diamond tool has to be fashioned in such a way that the [110] plane is in the direction of the maximum cutting force and then brazed onto a tool holder (Figure 230) [37] Diamond crystals are extremely smooth, can be lapped to a very fine cutting edge to produce finishes down to 10 in, often eliminating such operations as burnishing, polishing and buffing The tips of these tools are usually tailored and shaped for doing specific jobs (Figure 231) They are designed with radii 50 100% greater than the radii of comparable cemented carbide tools because the sharp cutting edge of a diamond tool remains unchanged over a long period of time [25] Generally, diamonds perform best at the highest possible speeds and light feed Diamond wear may occur by micro chipping (caused by thermal stresses and oxidation) and transformation to

Fig. 12-8.

Fig 230: Crystal orientation of a single-crystal diamond tool and typical geometry [37]

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