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DR-PCD
Application Examples
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PCD
- Non Ferrous machining
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Component:
Machine
Tool:
Material:
Operation:
Depth
of Cut:
Insert:
Surface
Speed:
Feed
Rate:
Surface
Finish:
Tool
Life:
Comments:
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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
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Component:
Machine
Tool:
Material:
Operation:
Depth
of Cut:
Insert:
Surface
Speed:
Feed
Rate:
Surface
Finish:
Tool
Life:
Comments:
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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
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Component:
Machine
Tool:
Material:
Operation:
Depth
of Cut:
Insert:
Surface
Speed:
Feed
Rate:
Surface
Finish:
Tool
Life:
Comments:
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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
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Component:
Machine
Tool:
Material:
Operation:
Depth
of Cut:
Insert:
Surface
Speed:
Feed
Rate:
Surface
Finish:
Tool
Life:
Comments:
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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
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Component:
Machine
Tool:
Material:
Operation:
Depth
of Cut:
Insert:
Surface
Speed:
Feed
Rate:
Surface
Finish:
Tool
Life:
Comments:
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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
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Component:
Machine
Tool:
Material:
Operation:
Depth
of Cut:
Insert:
Surface
Speed:
Feed
Rate:
Surface
Finish:
Tool
Life:
Comments:
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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
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Component:
Machine
Tool:
Material:
Operation:
Depth
of Cut:
Insert:
Surface
Speed:
Feed
Rate:
Surface
Finish:
Tool
Life:
Comments:
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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
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Component:
Machine
Tool:
Material:
Operation:
Depth
of Cut:
Insert:
Surface
Speed:
Feed
Rate:
Surface
Finish:
Tool
Life:
Comments:
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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
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Component:
Machine
Tool:
Material:
Operation:
Depth
of Cut:
Insert:
Surface
Speed:
Feed
Rate:
Surface
Finish:
Tool
Life:
Comments:
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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
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Component:
Machine
Tool:
Material:
Operation:
Depth
of Cut:
Insert:
Surface
Speed:
Feed
Rate:
Surface
Finish:
Tool
Life:
Comments:
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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
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Component:
Machine
Tool:
Material:
Operation:
Depth
of Cut:
Insert:
Surface
Speed:
Feed
Rate:
Surface
Finish:
Tool
Life:
Comments:
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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
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©
David Richards Engineering 2008
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