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Home >> Technical FAQs >> flange face milling with pcd inserts for heat exchanger surface finish machining

 

Flange Face Milling, shell and cover Surface Finish Machining with PCD Inserts

Machining doesn’t need to be difficult. Finding the right pcd (polycrystalline diamond) inserts heavily depends on what type of work needing to be done. Several different styles and cuts are available, each having a specific purpose and job completion goal. For high level types of jobs, it’s best to go with a pcd milling insert as the compounded 200mm diamond film is durable for the toughest work. Machine tools using polycrystalline diamond pcd tend to be more expensive than other types such as stainless steel. In the long run, pcd is tougher and operates better at higher temperatures than any other. Cost wise, pcd lasts longer than stainless steel, making it cost less over time.

These pcd diamond inserts hold up for work done on multiple surfaces and types of materials. It does require a proper precision cutting tool. In order to help eliminate overbuying, it’s recommended to invest in a strong cutting tool and use varying inserts. These tools can cut through aluminum, copper and brass. Nonmetal materials like rubber, plastics and ceramics are other styles of materials which can be cut through. The nonmetal sheets should be cut with a higher tolerance to preserve the life of the machine.

heat exchangers
flange and cover heat exchanger tube sheet tube sheets and stacked plate baffles

For pcd inserts on flange face milling and heat exchanger machining, there are a few choices. These are used for fine machining and cutting aluminum alloy. precision face milling cuts a surface and creates a smooth finish, depending on the style of insert used. Cutting can use circular, triangular or square shaped pcd milling inserts. By using these styles correctly, it helps prevent inefficient work habits and offset mistakes of the cutting tool. One perk to using the tipped pcd inserts and full faced pcd inserts for flange face milling is its ability to withstand heat. By attaching the proper insert, temperatures can reach higher levels while not losing the integrity of the materials being cut through. The types of jobs these inserts are used on vary, however, automobile work is acceptable. Machining engine blocks and cylinder heads are perfect examples for pcd milling and turning inserts.

pcd cutting inserts need to be fitted with the correct machine tool to handle cutting through various materials. Medium grain pcd material should be used for low silicon leveled aluminum and higher grain for aluminum made from higher amounts of silicon. A machine tool with positive geometrics works to the amount of force applied by the cutting tool. Depending on how deep the cut needs to be, a pcd tipped insert can be angled less or more. It’s recommended to reduce the angle and prevent harsh roughness of the insert. This keeps the cut smoother and makes the edge of the insert last longer.

If the client is unsure as to which insert would be a better fit for the machine being used, the staff at www.pcd-insert.com are readily available to answer all questions, we are willing to properly fit a machine with the proper tipped pcd turning inserts or full faced milling inserts, test for durability and wear loss. Instead of spending ample amounts of money up front, try purchasing samples. It’s a money saving method and allows for the client to figure out the proper insert for the job without wasting money. For further information on pricing, flange face milling, fittings or other products offered, feel free to visit our website content pages.

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