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PCD Inserts
Published:2019-06-14 10:48:54    Text Size:【BIG】【MEDIUM】【SMALL
Summary:PCD Insert is a type of super hard materials which made of tungsten carbide body together with PCD Blank (Poly-crystalline Diamond) through high temperature and high pressure. PCD Blank become PCD Insert after a series of process: cutting, brazing, tip grinding, inspecting. They are mainly used for precision machining of difficult-to-process non-ferrous and non-metallic materials.

1. What is PCD Insert?
PCD Insert is a type of super hard materials which made of tungsten carbide body together with PCD Blank (Poly-crystalline Diamond) through high temperature and high pressure. PCD Blank become PCD Insert after a series of process: cutting, brazing, tip grinding, inspecting.

2. PCD Inserts Types
PCD Inserts can be divided into the following types: ISO PCD Inserts, PCD Milling Inserts, Chip-breaker PCD Inserts, PCD Grooving Inserts. All types can be made as the customers’ requirements.
(1) ISO PCD Inserts
It usually belong to index-able CNC Inserts as ISO Models, which can be used with same holder with carbide inserts, such as CCGW09T304. It usually has 1 cutting tip, can be used for turning cylinder, inner bore, end surface, etc.
(2) PCD Milling Inserts
Common models like APMT, mainly used for high speed milling surface (milling speed above 3000m/min). It can obtain high surface roughness, and can obtain long tool life, which help the customers lower the processing costs.
(3) Chip-breaker PCD Inserts
It is make slot through laser on the cutting edge of a standard machine-clamp blade, mainly used for solve the chips problems, avoid the scratch on the component.
(4) PCD Grooving Inserts
It can include round tips and flat tips. The insert width will include 2mm, 3mm and 4mm, it also can be customized size as the customers’ requirements. It can be used for machining cylinder grooves, inner grooves, end surface grooves.

 

3. Machining Materials of PCD Inserts
PCD Inserts can be used for machining ferrous metal together with their alloy and some non-metal composites.
(1) Non-ferrous metal materials and their alloys: such as aluminum alloy, magnesium aluminum alloy, silicon aluminum alloy, copper alloy, copper, brass, tungsten carbide hard alloy, ceramics, etc.
(2) Non-metallic materials: such as composite materials, carbon fiber, glass fiber, graphite, wood, stone, urethane rubber, glass, reinforced plastic,coating, etc.

4. The applications of PCD Inserts
PCD Inserts are mainly used for precision machining of difficult-to-process non-ferrous and non-metallic materials.
(1) High Precision machining industries: PCD inserts are generally used for high precision cutting. Due to the high hardness of PCD material, high thermal conductivity, rapid heat transfer, low friction coefficient, and low affinity with non-ferrous metals, high precision can be obtained. high processing finish, can be used for glass mirror processing.
(2) Automobile industry: such as aluminum alloy piston, aluminum alloy wheel hub, aluminum alloy cylinder head and other parts, the main material is aluminum alloy, silicon aluminum alloy, high silicon aluminum alloy, mainly using PCD Inserts , PCD Grooving Inserts and PCD wheel hub turning tools. For this application, ADP010, ADP025 and ADP302 materials can meet the requirements of wear resistance, processing efficiency & quality, smoothness and precision.
(3) Wind power industry: At present, the main materials used in this field are fiber reinforced composite materials (CFRP, GFRP, AFRP, BFRP, etc.). The main materials of wind power blades are glass fiber and carbon fiber, mainly using PCD Inserts and PCD milling Inserts. Commonly used materials include ADP010, ADP025 and ADP302.
 
5. PCD Grade

Grade

Granularityμm

Characteristics

Application

ADP-SM

Sub-micron

Ultra-fine grain structure, strong edge sharpness and edge durability

High precision machining, mirror surface machining, suite for aluminum alloy that required high on the chipping performance, mainly used for machining Ti alloy and other composites.

ADP002

2μm

High cobalt content, Good electrical machine performance, excellent toughness, Good roughness machining, more convenient for complex tool processing

Mainly used for engrave milling cutter and thread cutting tool, and also cutting tools for wear-resistant parts, used in woodworking saws, particleboard and the tools for machining silicon aluminum alloy.

ADP005

5μm

Excellent electric spark and machinability, good toughness, wear resistance and edge quality

It suits for good surface quality processing, mainly used for machining PMMA, Silicon alloy and metal cell phone shell and used in the wood cutting tools, saws industry.

ADP010

10μm

Universal PCD Grade, good toughness and high abrasive resistance

Suit for single tool for rough machining, especially for wood molding, medium and low silicon aluminum alloy parts (such as piston).

ADP025

25μm

High wear resistance and edge quality

Suit for high Silicon Aluminum alloy, MMC, Tungsten carbide and ceramic, graphite,wear resistant parts,  mainly used in wood Wood finishing insert and saws.

ADP302

2~30μm

Mixed 2μm and 25μm,good wear resistance and edge quality and edges strength

It mainly used for machining MMC, high Silicon Aluminum alloy, high strength cast iron and other application.


6. PCD Inserts Cutting Parameters for Reference

(1) Cutting speed/Vc
PCD inserts can be used at very high spindle speeds. When machining different work piece materials, the cutting speed of PCD insert is also different. For example, PCD inserts can cut aluminum alloys at speeds up to 1000m/min, and the life is Dozens of times of tungsten carbide inserts.
(2) Feed Rate/Fr
The feed amount of the PCD Insert is different according to the work piece material, and can be recommended according to the cutting parameters of the tool manufacturer. For example, the feed amount of the aluminum alloy processed by the ADP010 material PCD blade is in the range of 0.03-0.5;
(3) Cutting Depth Applications
PCD inserts are often used for semi-finishing and finishing. The cutting depth of aluminum alloys processed by ADP010 is generally 0.1-3mm, and the depth of high silicon aluminum alloy (greater than 13% Si) is not more than 2.5mm.

The actual cutting parameters of the PCD insert should be determined according to the specific processing conditions.

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