PCD Application Examples

DR-PCD Application Examples

PCD - Non Ferrous machining

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Gear box casing

13% Silicon Aluminium

Toyoda Machining Centre

Face Milling

Typically 1.0 mm

SPKW 120404F EDR DR-PCD

800 m/min (2650 ft/min)

0.1 mm/rev/ tooth (0.004”/rev/ tooth)

0.8 micron Ra

6 months and still cutting

Axially adjustable cutter required to give best results

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Door Handle

Hard Brass

Hardinge Conquest SP T42 CNC Lathe

Profiling

Typically 0.25 mm (0.01”)

VCMW 160404F DR-PCD

300 m/min (1000 ft/min)

0.05 mm/rev (0.002”/rev

0.4 micron Ra

Thousands of components

Cosmetically superior finish

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Surface plate

Granite

Centre Lathe

Facing

Typically 0.5 mm (0.02”)

RNMN 090300F DR-PCD

60 m/min (200 ft/min)

0.1 mm/rev (0.004”/rev)

N/A

15 minutes contact

Good enough to go to lapping

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Brake Disc

Metal Matrix Composite

Mori Seiki SL25 CNC Lathe

Facing

Typically 0.5 mm (0.02”)

RNMN 090300F DR-PCD roughing CNMA 120408F DR-PCD finishing

300 m/min (1000 ft/min)

0.3 mm/rev (0.012”/rev) roughing - 0.2 mm/rev (0.008”/rev) finishing

1.6 microns Ra

15 minutes contact

Extremely abrasive material – 20% Silicon

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Body Scanner ring

Glass Reinforced Plastic

DSG Centre Lathe

Turning

Typically 1.5 mm (0.06”)

CNMA 120408F DR-PCD

200 m/min (660 ft/min)

0.2 mm/rev (0.008”/rev)

N/A

35 minutes contact

Extremely abrasive material – 25% glass

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Aircraft Control Surface

Carbon Fibre reinforced Composite

Wadkin Routing Machine

Trimming around form

Variable

Brazed 16 mm Slot Drill (2 Flute )

200 m/min (660 ft/min)

0.1 mm/rev / Tooth (0.004”/rev / tooth)

N/A

45 minutes contact

Extremely abrasive material

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Mould Tool

Graphite

Centre Lathe

Turning

Variable

VCMW 160404F DR-PCD

As fast as possible

0.1 mm/rev (0.004”/ rev)

N/A

30 times Tungsten Carbide

Extremely abrasive material

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Die Blank

Unfired Tungsten Carbide

Centre Lathe

Turning

Variable

DCMW 11T304F DR-PCD

As fast as possible

0.1 mm/rev (0.004”/ rev)

N/A

100 times Tungsten Carbide

Extremely abrasive material

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Kitchen Cupboard Door

Medium Density Fibreboard (MDF)

Wadkin Routing Machine

Producing raised centre panel

10 mm

Form Router (2 flute) – dynamically balanced to protect spindle

As fast as possible

0.1 mm/rev/tooth (0.004”/ rev / tooth)

N/A but surface must be suitable for coating

100 times Tungsten Carbide

Extremely abrasive material

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Turbocharger rotor

6% Silicon Aluminium

Okuma LCS 10 CNC Lathe

Trimming rotor vanes

Variable

DCMW 11T308F DR-PCD

500 m/min

0.1 mm/rev/tooth (0.004”/ rev / tooth)

Minimum burring

100 times Tungsten Carbide

The edge retention of PCD allows continuous burr free Production

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Lens for safety glasses

Polycarbonate

Special Purpose

Profiling lens to fit frame

Variable

Special 4 flute cutter

250 m/min

0.1 mm/rev/tooth (0.004”/ rev / tooth)

N/A

100 times Tungsten Carbide

Problem free automatic production