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6 Advantages of Using PCD Cutting Tools in Your Manufacturing Operations
In this article, I’m going to show you the advantages of PCD cutting tools. If you’re still hesitating about whether or not to use them for your machining, don’t worry. By the time you finish reading, you’ll have a better understanding of how to choose, based on your own needs, whether PCD cutting tools are the right option for you.
Table of Contents
Overview of PCD Cutting Tools
PCD (Polycrystalline Diamond) is a super high-performance material, and it’s 80 to 100 times harder than regular carbide tools. That’s why PCD cutting tools are considered the top choice for quality, precision, and durability. So, if your project needs faster cutting speeds, demands high precision, and involves mass production, PCD cutting tools are definitely worth considering. Now, let me dive into the benefits of using PCD cutting tools.
Benefits of the PCD Cutting Tools
1. Exceptional Wear Resistance of PCD Cutting Tools
PCD cutting tools are made by bonding synthetic diamond to a tungsten carbide base, through a process of high-temperature, high-pressure sintering of tiny diamond particles, which are bonded together by cobalt metal. Because of this, PCD cutting tools have exceptional wear resistance, and the high hardness of polycrystalline diamond makes them perfect for machining materials like titanium, used in aerospace, and composite materials like carbon fiber. They’re also great for machining automotive parts such as engine and transmission components made of aluminum and silicon-aluminum alloys. In the woodworking industry, PCD cutting tools have a much longer lifespan compared to traditional carbide woodworking mills, making them ideal for mass processing of laminates and hard or abrasive woods.
2. High Cutting Speed and Efficiency with PCD Cutting Tools
PCD cutting tools are much more efficient compared to carbide and HSS tool options. Typically, PCD cutting tools can run 10 to 15 times faster in terms of cutting rate. With this increase in speed, you can process more parts, and because of the durability of polycrystalline diamond, the quality of your products won’t be affected even after long hours of machining. Unlike solid carbide tools that wear out quickly, you can rely on PCD cutting tools to handle more work without causing downtime due to wear. And, you’ll still get consistent surface quality throughout.
3. Superior Surface Finish Quality Achieved by PCD Cutting Tools
For every metal manufacturer, surface finishing is a crucial process. Have you ever found yourself adding extra time for secondary finishing due to the machining process, increasing your time costs? PCD cutting tools, because of their sharpness, maintain excellent stability even at high cutting speeds. The parts they produce have exceptional surface finishes, which reduces the time spent on secondary polishing or tool changes for finishing. This ultimately improves overall production efficiency.
4. Long Cutting Lifetime of PCD Cutting Tools
PCD cutting tools offer a much longer tool life compared to traditional cutting tool materials like carbide or HSS. The excellent wear resistance of polycrystalline diamond means fewer tool changes when using PCD for CNC machining. As you know, machine downtime on the production line can significantly affect the regular production cycle. While PCD cutting tools are more expensive upfront than traditional carbide tools, their outstanding lifespan more than justifies the initial investment. Even though the high cost of PCD tools might make you hesitate in the beginning, when you consider long-term machining needs, PCD tools are often more cost-effective and the ideal solution for high-volume production. They’ll also significantly boost your return on investment.
5. Excellent Thermal Conductivity in PCD Cutting Tools
Another big advantage of PCD cutting tools is their excellent thermal conductivity, which directly improves machining performance in high-speed and complex parts. Thanks to this, PCD tools can perform dry machining on non-ferrous metals like aluminum and copper, as well as on composite materials and plastics. This means no cutting fluids are needed, reducing costs and minimizing environmental impact. Plus, dry machining prevents contamination of the workpiece. I’m sure, as a CNC technician, you’ve felt the frustration when cutting fluids accidentally splash onto your face. It can affect your breathing and overall comfort. Choosing PCD cutting tools reduces your reliance on cutting fluids, making it a more sustainable and cost-effective choice.
6. Versatility of PCD Cutting Tools in Material Processing
Another major advantage of PCD cutting tools is their versatility in handling a wide range of materials. When machining aluminum alloys, PCD tools maintain high cutting efficiency while preserving excellent precision and surface finish, which is especially important for the automotive industry, where lightweight materials are crucial. In the aerospace sector, when machining composite materials like carbon fiber or fiberglass, the sharp cutting edges of PCD tools prevent issues like delamination or fiber pull-out, which are common problems with traditional tools when machining these materials. Additionally, for industries that demand high precision, like electronics and medical sectors, PCD cutting tools can achieve excellent surface finishes on these delicate materials, reducing the need for secondary polishing and finishing. PCD tools can seamlessly switch between different materials without compromising performance, improving efficiency. They are truly an ideal choice for companies with diverse part machining needs.
Conclusion
Polycrystalline Diamond (PCD) cutting tools are perfect for machining non-ferrous metals like aluminum and copper alloys, various types of wood such as laminated and reinforced boards, composite materials like fiberglass and carbon fiber, as well as ceramics. For mass production, the outstanding durability and lifespan of PCD tools can help significantly reduce production costs.
SUNDI Tools is a professional cutting tool manufacturer. We are committed to providing high-quality cutting tools to our customers. Our engineering team has decades of industry experience and can offer you one-stop tooling solutions. Contact us now to learn more about our products!
