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how indexable pcd inserts improve machining operations?

Cutting tool inserts are fixed or fastened unto the tool cutter. Therefore, they are neither welded nor brazed to the tool body. This makes such tools moveable and indexable. Indexable pcd inserts can be flipped or rotated without affecting the functionality and dimensions of the tool cutter. In other words, the tool length and effective diameter will remain the same. Indexable inserts are commonly used for continuous milling and turning operations, especially when fresh cutting edges need to be used without the need to grind and sharpen the cutting edge. Here are some important benefits of indexable inserts.

Faster Machining
Indexable cutting inserts save time because different sides of the tool may be presented for cutting without requiring any time consuming set changes or re-programming of the CNC machine. For instance, while milling the face of cylinder blocks in a machine shop, the cutting tip will get hot after some time. However, the operation may continue without any interruption if the tool can be flipped over or rotated on the tool holder. This will ensure that the entire operation is completed faster and more blocks will be machined per day to give a higher level of efficiency and productivity.

Lower Cost of Operation
Many indexable pcd inserts are tipped tools. Tipped tools have one or more cutting edges that are made of a different material from the rest of the body. These types of tipped tools are commonly used for milling cutters, boring and turning tools. On tipped tools, only a small amount of abrasive material is welded or brazed to the rest of the tool insert. This makes it easier to manufacture and reduces the tooling cost. It also makes it easier to add special features like a wiper which helps to create a high quality surface finish.

Easy Tool Repair
Indexable tools can easily be repaired to save up to 60 percent of tooling costs. This is very significant for specialized cutters such as gear cutters, crankshaft cutters, and other cutters used to machine intricate components in automotive, aerospace, oil and gas, power generation, and ship building industries. In such cases, it is cheaper to re-grind or replace the tool inserts when they are worn out than to order for an entirely new set of cutting tools.

Longer Tool Life
Indexable tools usually have a relatively longer lifespan than their non-indexable counterparts. On this type of insert, cutting stresses, temperature and wear are distributed more evenly on different parts of the tool. Also, re-grinding and refurbishing can be carried out quicker and more effectively. For instance, when machining very hard aluminum super alloys used to produce engine parts, that are lightweight and offer better fuel efficiency, tipped indexable tools can make the machining of such parts very economical. They can withstand very high operating temperatures because they rotate and disperse the heat efficiently.

Conclusion
Indexable pcd inserts provide significant cost savings over tools that have only one cutting edge. When several edges of a cutting tool can be used for cutting, it increases the overall efficiency of the process and makes each operation more profitable.

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