Polycrystalline diamond (PCD) inserts are cutting tools used in a variety of industries for grinding and machining operations. PCD inserts are made from a composite of diamond powder and a metal binder, which is sintered under high pressure and temperature to create a very hard, wear-resistant material. PCD inserts can be used for machining operations on non-ferrous metals, composites, plastics, and carbide.
Characteristics Of PCD
The properties of PCD depend on the diamond crystals’ size, shape, and orientation, as well as the amount of metal present. The size of the diamond crystals affects the hardness and wear resistance of the PCD. The shape of the diamond crystals affects the thermal conductivity and toughness of the PCD. The orientation of the diamond crystals affects the strength and fracture toughness of the PCD.
The amount of metal in the PCD affects its wear resistance and thermal and electrical conductivity. The percentage of cobalt in the PCD can range from 0 to 30%. The percentage of nickel in the PCD can range from 0 to 70%. The balance of cobalt and nickel determines the properties of the PCD.
Uses And Common Shapes Of PCD Inserts
PCD inserts are used for machining non-ferrous metals, composite materials, stone, and glass. The inserts are available in various shapes and sizes to accommodate different machining applications. The most common shapes are square, rectangular, round, and hexagonal. The most common sizes are 1/4″, 3/8″, 1/2″, 5/8″, 3/4″, 1″, 1-1/4″, 1-1/2″, 2″, 2-1/2″, 3″, and 4″.
The Advantages Of PCD Inserts
PCD inserts offer several advantages over traditional cutting tools made from carbide or other materials. First, PCD inserts are much harder than carbide, which means they can maintain their cutting edge for longer. This results in increased productivity and fewer tool changes. Second, PCD inserts can be used to machine a wider range of materials, including non-ferrous metals, composites, plastics, and carbide. And third, because PCD inserts are so hard, they can withstand higher temperatures than other cutting tools, making them ideal for high-speed machining applications.
The Disadvantages Of PCD Inserts
While PCD inserts offer many advantages over traditional cutting tools, there are also some disadvantages. First, because they are made from diamond powder, they are quite expensive. Second, they can be difficult to sharpen or re-sharpen because they are so hard. And third, because they are made from diamond powder, they are susceptible to chipping or breaking if not used properly.
Conclusion:
PCD inserts are cutting tools made from a composite of diamond powder and a metal binder sintered under high pressure and temperature to create a very hard, wear-resistant material. PCD inserts offer several advantages over traditional cutting tools made from carbide or other materials, including increased productivity and the ability to machine a wider range of materials. However, PCD inserts also have some disadvantages to consider before using them for your next machining project. When you have difficulty choosing, contact us, and we will give you the best solution.
