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PCD Inserts (PCD Blade)
- 1. Let the worldno longer have difficult to machine materials ! PCD Inserts
- 2. Let the worldno longer have difficult to machine materials ! 1. PCD Insert material properties 2. PCD Insert Process Technology 3. Aption of PCD Insert 4. PCD Insert Models 5. Development of the PCD Inserts Contents
- 3. Let the worldno longer have difficult to machine materials ! PCD Insert material properties PCD Hardness can reach HV8000, about 80~120 times of carbide insert, The coefficient of thermal expansion of pcd insert is about 700W/mk, is about 1.5~9 times of carbide insert, even higher than copper and PCBN. The coefficient of friction of PCD insert is only 0.1~0.3( carbide insert is 0.4~1), so pcd insert can reduce the cutting force. The Affinity between PCD Inserts and non-ferrous metal and non-metal materials is small, and will be easily produce BUE, Excellent Characteristics High Thermal conductivity Low coefficient of friction High Hardness Low coefficient of thermal expansion
- 4. Let the worldno longer have difficult to machine materials ! PCD Materials Grade and Characteristics Insert Grade Process Average Size Product Features Application Industry Microstruc ture CDW10 Ultra Precision 2μm High Surface Roughness, Ultra precision Suit for low silicion Aluminum alloy, Copper alloy CDW20 Rough/Finis h 10μm Higher surface finish, abrasion resistance and impact resistance Widely used for semi-content silision aluminum alloy, Copper alloy, ferrous metal and some composites CDW30 Roughing 2-25μm High abrasive resistance Suit for abrasive resistant materials and high content silicion aluminum alloy
- 5. Let the worldno longer have difficult to machine materials ! Design princples of PCD Cutting Tools Choose Materials Reasonable particle Reasonable Thickness Insert Grade PCD Particle Machining Process CDW10 2μm Finishing CDW20 10μm Semi-fnishng CDW30 25μm Roughing Typically, PCD composite sheet layer thickness need about 0.3 ~ 1.0mm, total thickness will be about 2~8mm.Thin PCD layer thickness is conducive to blade EDM.
- 6. Let the worldno longer have difficult to machine materials ! Polycrystalline diamond (PCD) blade manufacturing process Diamond Powder 高温高压下合成 复合片 PCD复合片的研磨 PCD复合片的制造 PCD刀片的加工 Cutting Blade PCD刀片的焊接 Grinding Edges Diamond Powder Polycrystalline diamond Grinding PCD Compound Insert PCD Blade Process Brazing High temperature High pressure
- 7. Let the worldno longer have difficult to machine materials ! PCD Insert ISO Models VCGT VCGW VBGW VBGT TCGT TCGW TPGW TPGT CCGT CCGW CPGW CPGT DCGT DCGW DPGW DPGT WCGT WCGW RPGW RCGW TPGN
- 8. Let the worldno longer have difficult to machine materials ! Indexable Insert Identifcation Table
- 9. Let the worldno longer have difficult to machine materials !
- 10. Let the worldno longer have difficult to machine materials ! Other Type PCD Insert
- 11. Let the worldno longer have difficult to machine materials ! PCD Milling Inserts
- 12. Let the worldno longer have difficult to machine materials ! Customized PCD Inserts
- 13. Let the worldno longer have difficult to machine materials ! The cutting parameters of PCD Inserts Machining Materials Process PCD Grade Cutting Parameters Cutting Speed Feed Rate Cutting Depth Vc（m/min） Fr（mm/r） ap（mm） Aluminum Alloy 4-8%Si Turning CDW10/CDW20 900-3500 0.1-0.4 0.1-0.4 Milling 1000-5000 0.1-0.3 0.1-0.3 9-13Si Turning CDW10/CDW20 600-2400 0.1-0.4 0.1-0.4 Milling 700-3000 0.1-0.3 0.1-0.3 ＞13%Si Turning CDW20/CDW30 300-700 0.1-0.4 0.1-0.4 Milling 400-900 0.1-0.3 0.1-0.3 Metal Based Composites A1/10-20%Si Turning /Milling CDW20 300-600 0.1-0.4 0.2-1.5 Copper Alloy Copper, Zn Turning/Milling CDW10 400-1260 0.03-0.3 0.05-2.0 Turning/Milling CDW20 400-1200 0.05-0.3 0.05-2.0 Tungsten Carbide ＜16%Co Turning CDW20/CDW30 20-40 0.1-0.25 0.1-1.0 Ceramic Turning CDW20 70-100 0.1-0.4 0.2-1.0 Wood Turning/Milling CDW10 1000/4000 0.1-0.4 0.1-0.4 Composite Carbon Firber Turning/Milling CDW20 200-2000 0.05-0.3 0.1-3.0
- 14. Let the worldno longer have difficult to machine materials ! The Application of PCD Inserts （1）Machining Non-ferrous metal （2）Machining Non-metal materials When machining copper, zinc, aluminum and other non-ferrous metals and their alloys, the material easily adheres to insert. Due to the low friction coefficient of PCD and the small affinity with non-ferrous metals, PCD tool can effectively prevent the metal from binding with the tool, and the blade deformation and can obtain good surface quality. When Processing glass fiber reinforced plastic, silicon packing materials, hard carbon fiber / epoxy composite materials, carbide insert will wear serious tool, difficult to process, and PCD tool have high hardness, wear resistance, high processing efficiency.
- 15. Let the worldno longer have difficult to machine materials ! Wood Automotive Ferrous MetalsAerospace 3C IndustryGraphite The Application of PCD Inserts
- 16. Let the worldno longer have difficult to machine materials ! Some typical Component that can use PCD Inserts Automotive Engine Pistons, normally pcd inserts can machine the grooves, pin hole, endsurface, Cylindrical surface,ect.
- 17. Let the worldno longer have difficult to machine materials ! Some typical Component that can use PCD Inserts Automotive Wheel Hub,no matter for Automotive parts or Motorcycle, PCD Inserts can obtain good surface roughness,they can be made with many different radius, such as R1.2,R2.5,R3.0,R4.0, ect. The ISO Models usually are VCGW160412 PCD Inserts.
- 18. Let the worldno longer have difficult to machine materials ! Application case for machining Engine with PCD Insert In recent years, Aluminum engine block begin to become light weight, small size, high precision,ect. Becasue of high hardness, low thermal expansion coefficient and other characteristics, pcd inserts have been the most suitable cutting tool materials for machining Aluminum alloy component. Comparing with ceramic cutters or carbide insert, the cutting speed can improve several times,and the tool life will be better. The following is one application case: Machining Mateirals: AlSi9Cu3（Fe） Cutting Condition: Interrupt Cut Cutting Depth:0.5~0.7mm Machining Length:735mm Tool Life:30000pieces
- 19. Let the worldno longer have difficult to machine materials ! Thanks ! Zhengzhou Halnn Superhard Materials Co.,Ltd Web:www.halnncbn.com Email:halnntools@gmail.com Wechat:Halnntools Whatsapp:+8618695866134