Polycrystalline diamond (PCD) inserts are cutting tools used in a variety of industries for grinding and machining operations. PCD inserts are made from a composite of diamond powder and a metal binder, which is sintered under high pressure and temperature to create a very hard, wear-resistant material. PCD inserts can be used for machining operations on non-ferrous metals, composites, plastics, and carbide.
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The properties of PCD depend on the diamond crystals&#; size, shape, and orientation, as well as the amount of metal present. The size of the diamond crystals affects the hardness and wear resistance of the PCD. The shape of the diamond crystals affects the thermal conductivity and toughness of the PCD. The orientation of the diamond crystals affects the strength and fracture toughness of the PCD.
The amount of metal in the PCD affects its wear resistance and thermal and electrical conductivity. The percentage of cobalt in the PCD can range from 0 to 30%. The percentage of nickel in the PCD can range from 0 to 70%. The balance of cobalt and nickel determines the properties of the PCD.
PCD inserts are used for machining non-ferrous metals, composite materials, stone, and glass. The inserts are available in various shapes and sizes to accommodate different machining applications. The most common shapes are square, rectangular, round, and hexagonal. The most common sizes are 1/4&#;, 3/8&#;, 1/2&#;, 5/8&#;, 3/4&#;, 1&#;, 1-1/4&#;, 1-1/2&#;, 2&#;, 2-1/2&#;, 3&#;, and 4&#;.
PCD inserts offer several advantages over traditional cutting tools made from carbide or other materials. First, PCD inserts are much harder than carbide, which means they can maintain their cutting edge for longer. This results in increased productivity and fewer tool changes. Second, PCD inserts can be used to machine a wider range of materials, including non-ferrous metals, composites, plastics, and carbide. And third, because PCD inserts are so hard, they can withstand higher temperatures than other cutting tools, making them ideal for high-speed machining applications.
While PCD inserts offer many advantages over traditional cutting tools, there are also some disadvantages. First, because they are made from diamond powder, they are quite expensive. Second, they can be difficult to sharpen or re-sharpen because they are so hard. And third, because they are made from diamond powder, they are susceptible to chipping or breaking if not used properly.
PCD inserts are cutting tools made from a composite of diamond powder and a metal binder sintered under high pressure and temperature to create a very hard, wear-resistant material. PCD inserts offer several advantages over traditional cutting tools made from carbide or other materials, including increased productivity and the ability to machine a wider range of materials. However, PCD inserts also have some disadvantages to consider before using them for your next machining project. When you have difficulty choosing, contact us, and we will give you the best solution.
02 February
Benefits of using indexable inserts
One of the most significant benefits of using indexable tools is that cutting edges can be updated don&#;t need remove the tool from the production site.
The renewal just needs to loosen the clamped inserts, rotating or turning the insert (transposing) to a new cutting edge, or installing a brand new inserts to replace the completely worn one.
Unlike turning tools, indexable milling cutter bodies from different tool manufacturers have different inserts shapes and grooves, and users can only purchase milling cutters from the respective tool manufacturers.
Most tool manufacturers can customize off-label indexable forming tools. However, forming milling tools is still an effective method to complete complex shapes, and can improve production efficiency and reduce tool inventory.
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In general, parts with steps, arcs, and chamfering features require multiple tools to be machined together. If the combined indexable forming tool is used, the production time, tool inventory and part quality can be shortened.
Disadvantages of indexable inserts
Indexable cutting tools also have disadvantages.
Inserts are usually made of high pressure pressed alloy powder and binder in a mold. After pressing and forming, it is sintered at a high temperature to combine the alloy powder with other materials and make the blade have a certain strength.
The pressed Insert has higher edge strength than the grinding Inserts. Although the Inserts are stronger the cutting edge is not sharp enough, which limits the effective shallow cutting depth and thus makes finishing more difficult.
For a milling tool with more than one Insert, the change in the groove of the blade and the size of the Inserts will cause the cutting edges of the different Inserts to be in different planes. The result is a poor surface finish or obvious leaping joints. In this case, only use another type of tool for fine processing.
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