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PCD inserts for full face milling

Aluminum alloy automotive cylinder head

Full top face milling pcd insert has a polycrystalline diamond layer on the insert surface, compound with presintered tungsten carbide base as a substrate, it eliminate the brazing joint with less delamination. Applications for fine machining aluminum alloy, full face milling automobile cylinder head, engine block, turning cast aluminum, tungsten carbide, copper and non metals material.

Full face PCD milling inserts

full top surface polycrystalline diamond milling inserts

Today’s current metal cutting climate is focused on low cost and high production rates when it comes to a company’s cutting tools. If you are one of these companies, or maybe you are just interested for your personal needs, you may be in the market for a top surface pcd insert. These inserts are made for cutting aluminum alloys to benefit the current tool holders, but have a huge advantage in hardness and working service time when compared to traditional ceramic or tungsten carbide cutting tools. pcds perform a longer tool life when compared to previous machining inserts and is much more cost friendly when looked at as cost per part. Full top surface pcd, which stands for Polycrystalline Diamond, inserts and is probably the most cost efficient, high precision cutting tools as inserts employed to machine a multitude of materials such as; non-ferrous metals and non-metallic metals. A few non-ferrous metals include copper, aluminum, brass and bronze. Non-metallic materials include hard rubber, ceramics, chipboard, and reinforced plastics. pcd can be used for finishing work or roughing, but it is usually best used when high surface finishes or tight tolerances are needed. It has an exceptionally long life span for the tool world and is an exceptional tool that will both elongate the life of your machine and enhance the quality of your products. Now pcd material are widely used in the field of automobile, motocycle, airplane for turning and milling gearbox, engine block and cylinder head. as these high hardness grade aluminum alloy usually contain si>12%, only the coarsest grade pcd material with great wear resistance is the most suitable cutting tools.

When choosing a polycrystalline diamond insert, there are three different grades of crystal toughness and size, but keep in mind the higher the grade the lower the edge quality. The finest grade is used when advanced surface finish is the goal, the middle grade is for component finishing, and the coarsest grade is for when finish is not important, but focuses on abrasive resistance.

1. The first grade is 0.5~10µm, it is of ultra-fine grains and has a substantial sharpness to the tool edge. This type of pcd is best used with plastics, aluminum applications (in the sense of a low micro fine finishing), and with wood. And 8~9µm pcd inserts is suitable for machining si<12% aluminum alloy, 4~5µm pcd inserts is suitable for machining pure aluminum.
2. The second grade is 10~20µm, this grade is made of a fine grain diamond with a high range for abrasion resistance. This grade is best used against high silicon aluminum, fiberglass, graphite epoxy, carbon, and wood. And 10~25µm pcd inserts is suitable for machining si>12% high silicone aluminum alloy and tungsten carbide.
3. The last grade is 20~50µm, it is a high density material made out of micro diamond pieces. It has superior hardness and has a sharp edge. It is best used against copper, hard rubber, wood. The bigger of pcd material grain size, the better of wear resistance, and the cutting edge will be minor chip, so not suitable for premium high quality precision cutting tools.

For a general turning insert, you want a pcd that can provide a quality surface finish that also has a good quality edge. It should also be wear resistant and with a medium strength of impact. If you are needing pcd for roughing and finishing turning, look for properties such as good impact strength and very wear resistant. pcd milling inserts are the optimal choice for effective milling of both non-metallic materials and non-ferrous metals. These inserts will allow you to hold and keep close tolerances, increase productivity, and obtain great surface finishes with your machine.

Full top surface pcd inserts are various with more insert shapes, the blanks are available with “A” and “W” ISO style pin lock holes, and full face pcd insert features good wear resistance and impact stength, it is widely used for cnc turning and milling as an indexable insert, it has better heat absorption capacity, and be able to work at certain higher temperatures than tipped pcd inserts, facilitate larger depth of cut compared to the same size tipped pcd inserts. If you are unsure of what is needed, our specialists can help you and guide you to choose the ISO format numerical code, as long as you tell us which type of material needs to be machined. Or provide us a drawing , a used sample of what is currently being used as an insert. If you are in need of a milling cutter, advise us the amount of tips you will need, and details about the machine you are using such as feed range and cutting speed.