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   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

 

 

 

 

 

 

© David Richards Engineering 2008