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Home >> Technical FAQs >> how to select the right pcd cutting tools?

 

how to select the right pcd cutting tools?

Polycrystalline diamond pcd cutting tools are now rapidly replacing the old carbide cutting tools for machining non-ferrous components. pcd tool inserts allow faster cutting and feed speeds compared to other cutting tool materials. They reduce the amount of scrap and provide better workpiece quality with excellent surface finish. Also, these tools optimize the efficiency of existing machines and increase production capacity. Thus, they are very economical and cost effective. When choosing pcd cutting tools, however, proper care needs to be taken to ensure that the best tool insert is chosen for each machining operation. Here are some important factors to consider when selecting pcd cutting tools.

Type of Working Material
Non-ferrous materials usually consist of a combination of metallic and non-metallic elements. For instance, in the automotive and aerospace industries, the aluminum is combined with other elements such as vanadium, silicon and chromium. These materials are commonly sintered to boost strength, hardness and durability. So it is important to know the material characteristics like the silicon content, hardness, and tensile strength before choosing a cutting tool. For non-metallic materials and composites, the composition and layers of the material should be carefully studied and analyzed. In some cases, composite materials must be machined with tools designed for interrupted operations.

Workpiece Dimensions
pcd tools have over 16 ISO standard shapes that have been created to effective cut component parts with any dimension. Some of these shapes include: diamond, round, triangle, square, rectangle, parallelogram, pentagon, hexagon, and octagon. Shapes like diamond, hexagon, and parallelogram also have variations with different internal angles. Each of these shapes has a designated alphabet that is used to identify it. For instance, to machine components that have areas that are hidden or obscured, diamond shaped pcd inserts with 35 degree angles may be used. For external turning or face milling, multi-tipped square-shaped inserts can provide more efficient machining.

Type of Operation
On a single component part, such as an automotive cylinder head, a machinist must carry out multiple operations. Such operations usually include: milling, boring, drilling and reaming. Each of these operations will be performed in one or more stages including, roughing, semi-finishing, and finishing operations. Roughing operations usually require the removal of a substantial portion of material at a high speed. So a cutting tool with a longer cutting edge and a chip breaker would be more appropriate for such operations.

Cutting Conditions
Cutting conditions such as the feed rate, depth of cut, feed and cutting speeds required to complete a machining operation, are essential factors in the selection of suitable pcd cutting tools. Running your cutting tools at the right speed and feed rate will prolong tool life and give you a high quality surface finish. It will also help you to optimize the overall cost of the operation. Before you can determine the optimal cutting conditions for any operation, you should get recommendations from various technical data sheets and then run a short test to determine the optimum cutting data to use for your machine and the workpiece.

Conclusion
If the conditions listed above are carefully considered before choosing pcd cutting tools, the overall machining process will be carried at an optimal cost with excellent surface quality. This is particularly important in high volume operations where a little cost savings on one operation can lead to a significant reduction of the total cost.

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