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pcd insert, pcd milling insert，pcd endmills and pcd chipbreaker insert pcd
- 1. Let the worldno longer have materials that difficult to machine !
- 2. Let the worldno longer have materials that difficult to machine ! Part 1 PCD Insert material properties Part 2 PCD Insert production process Part 3 PCD Insert ISO Models Part 4 Choosing the right PCD Insert Part 5 The Application of PCD Inserts Content
- 3. Let the worldno longer have materials that difficult to machine ! PCD Insert material properties
- 4. Let the worldno longer have materials that to difficult machine ! PCD Insert Materials Properities Thremal Conducdivi ty Low thermal expansion coefficient High refractive index High Hardness Low friction coefficient Radioactiv e inertia Perfor mance
- 5. Let the worldno longer have materials that to difficult machine ! Halnn PCD Grade and Characteristics Grade Granularity （μm） Characteristics Application Microstructur e CDW850 Submicron Ultra-fine grain structure, strong edge sharpness and edge durability High precision machining, mirror surface machining, suite for aluminum alloy that required high on the chipping performance, mainly used for machining Ti alloy and other composites CDW002 2μm High cobalt content, Good electrical machine performance, excellent toughness, Good roughness machining, more convinent for complec tool processing Mainly used for engrave milling cutter and thread cutting tool, and also cutting tools for wear-resistant parts, used in woodworking saws, particleboard and the tools for machining silicon aluminum alloy CDW005 5μm Excellent electric spark and machinability, good toughness, wear resistance and edge quality It suits for good surface quality processing, mainly used for machining PMMA, Silicion alloy and metal cell phone shell outlin and used in the wood cutting tools, saws industry CDW010 10μm Universal PCD Grade, good toughness and high abrasive resisitance Suit for single tool for rough machining, especially for wood molding, medium and low silicon aluminum alloy parts (such as piston). CDW025 25μm High wear resistance and edge quality Suit for high Silicion Aluminum alloy, MMC, Tungsten carbide and ceramic, graphite,wear resistant parts, mainly used in wood Wood finishing insert and saws CDW302 2~30μm Mixed 2μm and 25μm,good wear resistance and edge quality and edges strength It mainly used for machining MMC, high Silicion Aluminum calloy, high strength cast iron and other application.
- 6. Let the worldno longer have materials that difficult to machine !
- 7. Let the worldno longer have materials that to difficult machine ! Design Principles of PCD Insert Choice the right PCD Materials Reasonable PCD granularity Reasonable PCD Thickness Halnn PCD Grade Granularity CDW085 micro μm CDW002 2μm CDW005 5μm CDW010 10μm CDW025 25μm CDW302 2~30μm PCD layer thickness usually be about 0.3~1.0mm, and the total thickness is about 2~8mm.
- 8. Let the worldno longer have materials that to difficult machine ! PCD Manufacturing process Diamond powder Polycrystalline diamond PCD Composite Grinding PCD composite film Machining PCD Composite PCD Cutting PCD Brazing PCD Tips Grinding High temperature High pressure
- 9. Let the worldno longer have materials that to difficult machine ! Process Method laser EDM Ultrasonic In the above processing methods, EDM will be better. In the process with working fluid conditions, it uses pulse voltage to make the working fluid near the electrode metal form a discharge channel, and produce the partial discharge sparks, the instantaneous high temperature will make polycrystalline diamond melt, fall off, so as to form the required triangle, rectangle or square pcd blanks. Cutting Process of PCD Composite
- 10. Let the worldno longer have materials that to difficult machine ! Brazing Method of PCD insert Process Method High-frequency induction brazing Vacuum brazing At present, low cost high frequency induction brazing is widely used in PCD blade welding. In the actual processing, we can control the welding temperature (generally should be lower than 700 ℃) according to the holding time and the depth of PCD redness . High-frequency welding using automatic welding technology, welding efficiency, good quality, continuous production. laser Brazing
- 11. Let the worldno longer have materials that to difficult machine ! Cutting Process of PCD Composite Process Method Grinding Process Electrical processing The high hardness of PCD leads to very low material removal rates (even one ten thousandth of the cemented carbide removal rate). As the grinding wheel hardness is near to pcd, so the principle is complicated. Electric spark grinding (EDG) technology isn't hardly affected by the hardness of the workpiece, soEDG grinding has great advantages. With the continuous development of electric spark grinding technology, EDG technology will become a major development direction of PCD grinding.
- 12. Let the worldno longer have materials that difficult to machine !
- 13. Let the worldno longer have materials that to difficult machine ! PCD Inserts Models（ISO）
- 14. Let the worldno longer have materials that to difficult machine ! PCD Chipbreaker Inserts
- 15. Let the worldno longer have materials that to difficult machine ! PCD Chipbreaker Insert Models ISO Models Chipbreaker 1 Chipbreaker 2 CCGT CPGT DCGT RCGT ISO Models Chipbreaker 1 Chipbreaker 2 SCGT TCGT VBGT VCGT
- 16. Let the worldno longer have materials that to difficult machine ! PCD Turning Insert CDW010 CDW010 C D W 025
- 17. Let the worldno longer have materials that to difficult machine ! PCD Millling Insert
- 18. Let the worldno longer have materials that to difficult machine ! PCD Insert with one side
- 19. Let the worldno longer have materials that to difficult machine ! Customized PCD Insert
- 20. Let the worldno longer have materials that difficult to machine ! Part 4 Choosing the right PCD Insert
- 21. Let the worldno longer have materials that to difficult machine ! Choose the right pcd grade depending on the processing characteristics and the application details Grade Granularity （μm） Characteristics Application CDW850 Submicron Ultra-fine grain structure, strong edge sharpness and edge durability High precision machining, mirror surface machining, suite for aluminum alloy that required high on the chipping performance, mainly used for machining Ti alloy and other composites CDW002 2μm High cobalt content, Good electrical machine performance, excellent toughness, Good roughness machining, more convinent for complec tool processing Mainly used for engrave milling cutter and thread cutting tool, and also cutting tools for wear-resistant parts, used in woodworking saws, particleboard and the tools for machining silicon aluminum alloy CDW005 5μm Excellent electric spark and machinability, good toughness, wear resistance and edge quality It suits for good surface quality processing, mainly used for machining PMMA, Silicion alloy and metal cell phone shell outlin and used in the wood cutting tools, saws industry CDW010 10μm Universal PCD Grade, good toughness and high abrasive resisitance Suit for single tool for rough machining, especially for wood molding, medium and low silicon aluminum alloy parts (such as piston). CDW025 25μm High wear resistance and edge quality Suit for high Silicion Aluminum alloy, MMC, Tungsten carbide and ceramic, graphite,wear resistant parts, mainly used in wood Wood finishing insert and saws CDW302 2~30μm Mixed 2μm and 25μm,good wear resistance and edge quality and edges strength It mainly used for machining MMC, high Silicion Aluminum calloy, high strength cast iron and other application.
- 22. Let the worldno longer have materials that to difficult machine ! The cutting condition of PCD Insert Component Materials Recommend PCD Grade Cutting Condition Vc（m/min） Fr（mm/r） ap（mm） Aluminum alloy 4-8%Si CDW010 CDW302 CDW005 CDW850 100-5000 0.03-0.5 0.1-3.0 9-13%Si CDW010 CDW302 CDW850 100-3000 0.03-0.5 0.1-3.0 ＞13%Si CDW010 CDW302 CDW025 CDW850 100-2500 0.03-0.4 0.1-2.5 Copper alloy Copper, zinc, brass CDW010 CDW302 CDW025 CDW850 100-1000 0.03-0.3 0.1-3.0 Titanium alloy CDW850 CDW005 100-200 0.05-0.2 0.1-2.0 Tungsten Carbide Co < 16% CDW302 CDW025 CDW010 15-40 0.1-0.25 0.1-1.0 Co > 16% CDW302 CDW025 CDW010 10-30 0.03-0.1 0.05-0.3 Reinforced plastic 100-1000 0.05-0.3 0.1-2.0 Wood CDW010 CDW302 CDW005 CDW002 100-4000 0.1-0.4 0.1-3.0 Graphite CDW302 CDW025 CDW010 100-600 0.1-0.5 0.05-2.0 Metal matrix composites A1/10-20%Si CDW302 CDW025 CDW010 300-600 0.1-0.4 0.2-1.5 Composite Carbon Finber CDW302 CDW025 CDW010 200-2000 0.05-0.3 0.1-3.0
- 23. Let the worldno longer have materials that to difficult machine ! PCD Insert with Chipbreaker In the process of semi-finish and finish turning aluminum alloy, chipbreaker insert will perform excellently: (1)Solved the chips problems, and improve the working efficiency (2)With high strength materials, achivieve stable process and obtain long tool life. The main factors that we need to consider when choose pcd chipbreaker insert: 1）To make chips breaking smooth and without affecting normal cutting; 2）Need to control the chips volume, make it easily to handle with. 3）The chips need to be removed without winding the workpiece
- 24. Let the worldno longer have materials that difficult to machine !
- 25. Let the worldno longer have materials that to difficult machine ! The application details of PCD Insert （1）Ferrous metal （2）Non-metal materials When machining Copper, Zinc, Aluminum ect ferrous metal and other alloy, the materials will be easily adhesion tool, it will be difficult to machine. Because of the low Coefficient of friction and the small Affinity with metal of the pcd tools,we can get higher surface quality and slove the problems, improve the efficiency. When processing fiber glass-reinforced plastics, silicon-filled materials, and hard carbon fiber/epoxy resin composites, Tunsten carbide insert will be easily wear and difficult to machine, PCD tools will have high hardness, good abrasive resistance and high process efficiency.
- 26. Let the worldno longer have materials that to difficult machine ! Application Industry of PCD insert Aerospace Automotive Industry ferrous metal3C Industry
- 27. Let the worldno longer have materials that to difficult machine ! Application of PCD Insert——Aluminum alloy part in automotive industry PCD Inserts are widely used in automotive industry, for example, machining Engine, oil hole and engine block, it will need pcd insert. Because of high content of Silicion, it will require high on the hardness and the usage life of the cutting tools. Only with PCD Insert, it can promise the process efficiency and quality.
- 28. Let the worldno longer have materials that to difficult machine ! PCD Insert for Aluminum alloy part---Automotive Pistons In order to improve the performance of the Automotive engine, Most automotive pistons will change the materials from Aluminum with low content silicion to Aluminum with medium or high content silicion which improve the components' hardness and abrasive resistance. PCD Insert with excellent performance is widely used for aluminum alloy.
- 29. Let the worldno longer have materials that to difficult machine ! PCD Insert for Aluminum alloy part---Automotive Wheel Hub Aluminum alloy are widely used because of its excellent performance, and more and more widely used in industry. Aluminum alloy wheel hub, because of its light weight, high precision, easily process, have been used by many automotive manufacturers. The following is some common pcd inserts for machining automotive wheel hub.
- 30. Let the worldno longer have materials that to difficult machine ! PCD Insert--- Machining Aluminum alloy engine block Component：Aluminum alloy engine block Materials：AlSi9Cu3（Fe） Cutting condition: Interrupt cutting Cutting Depth:0.5~0.7mm Machining Length:735mm Tool Life:30000 pieces Performance: Comparing tungsten carbide insert and ceramic cutters, the cutting speed with pcd milling insert can be much higher, and the tool life also will be longer.
- 31. Let the worldno longer have materials that to difficult machine ! About Halnn Halnn superhard, as China's pioneer in the production of super-hard tool, the early brittle and hard materials with cubic boron nitride cutting tools and high-grade diamond for the research, the super-hard tool in the academic community enjoys a high reputation, especially in the " Turning instead of Grinding, "ultra-high hardness heavy cutting, high-speed processing of cast iron and other sub-sectors to lead the industry first- class level, both at home and abroad have their own advantages. At the same time, according to the natural resources of Henan Superhard Materials Institute , Halnn continue to launch new CBN / PCD tools and other new materials tools in the 3C industry, aerospace, nuclear and military fields .
- 32. Let the worldno longer have materials that difficult to machine ! web: http://www.halnncbn.com Email:halnntools@gmail.com Whatsapp:+8618695866134 Thanks !