PCD Inserts: Standard & Custom Solutions

Unlock Peak Machining Performance with Advanced PCD Inserts

Maximize your productivity, tool life, and surface finish quality when machining non-ferrous metals and highly abrasive materials with our premier range of Polycrystalline Diamond (PCD) cutting tool inserts. As specialists in PCD tooling technology, we provide both industry-standard solutions and bespoke designs engineered for your unique operational requirements.

What is PCD and Why Use It?

Polycrystalline Diamond (PCD) is a synthetic diamond composite produced under high pressure and high temperature. It fuses selected diamond particles onto a cemented carbide substrate, resulting in a cutting tool material that combines the extreme hardness and wear resistance of diamond with the toughness of carbide.

Choose PCD inserts for significant advantages in specific material groups:

• Exceptional Wear Resistance: Dramatically extends tool life compared to traditional carbide tools, especially in abrasive materials like high-silicon aluminum, metal matrix composites (MMC), carbon fiber reinforced plastics (CFRP), and graphite.
• Superior Surface Finish: The ability to maintain sharp cutting edges allows for high-quality finishes, often eliminating secondary finishing operations.
• High Thermal Conductivity: Effectively draws heat away from the cutting edge, preventing thermal damage and maintaining tool integrity at high speeds.
• Increased Productivity: Enables significantly higher cutting speeds and feed rates, drastically reducing cycle times and cost-per-part.
• Chemical Stability: Ideal for non-ferrous materials where chemical reactions with the tool are less of a concern.

Typical Applications & Industries

Our high-performance PCD inserts are engineered to excel in demanding machining operations across various key industrial sectors. They provide optimal solutions for working with non-ferrous metals (like aluminum alloys, copper, brass) and highly abrasive non-metallic materials (such as composites and graphite). Key application areas and common insert types include:

• Automotive Industry:
  • High-speed milling and turning of aluminum engine blocks, cylinder heads, pistons, transmission cases, and wheels. Commonly utilizes PCD turning inserts (e.g., CNMG, WNMG for roughing; CCGT, DCGT, VBGW for finishing) and face/shoulder milling inserts (e.g., SEHT, APKT styles).
  • Precision machining of other non-ferrous powertrain and chassis components.
• Aerospace Industry:
  • Machining of aluminum alloy structural components (airframes, ribs, spars). Often employs similar turning and milling PCD inserts as the automotive sector (e.g., CCGT, APKT).
  • Milling, turning, or trimming of abrasive composite materials (CFRP, GFRP). May use positive rake PCD inserts (e.g., TCGT, VCGT) or specialized milling geometries alongside rotary tools.
• Mold & Die Industry:
  • High-speed milling of graphite electrodes for Electrical Discharge Machining (EDM). A primary application for robust PCD milling inserts like APKT, RCGX (round inserts), and specific face mill insert types.
  • Direct milling and finishing of aluminum molds and dies using various PCD milling inserts.
• Electronic Industry:
  • High-speed milling and finishing of aluminum alloy casings, frames, and components for smartphones, laptops, etc. Frequently uses sharp-edged, positive rake PCD inserts (e.g., CCGT, VCGT, TCGT) for high-gloss finishes and smaller milling inserts (e.g., APKT style).
  • Machining copper or aluminum heat sinks and connectors.

Comprehensive Range of PCD Insert Solutions

We offer a complete portfolio to meet diverse manufacturing needs:

Standard ISO PCD Inserts

Benefit from interchangeability and reliability with our extensive selection of ISO standard PCD inserts. We cover a vast array of geometries suitable for turning, milling, grooving, and boring operations. Common configurations include:

• Turning (80° Rhombic): CNMG, CNMA, CNMM, CCGW, CCMW, CCMT, CCGT
• Turning (55° Diamond): DNMG, DNMA, DNMM, DCGW, DCMW, DCMT, DCGT
• Turning (60° Triangle): TNMG, TNMA, TNMM, TCGW, TCMW, TCMT, TCGT
• Turning (35° Diamond): VNMG, VNMA, VNMM, VBGW, VBMW, VCMT, VCGT
• Turning (Square): SNMG, SNMA, SNMM, SCGW, SCMW, SCMT, SCGT
• Turning (Round): RCMT, RCMW, RCGX, RNGN
• Milling (Indexable): APKT, APMT, SEHT, SEHW, SEKN, SNHW, RCGX, RCGT, SPKN, TPKN
• Grooving & Parting: Standard geometries often available based on system (e.g., Top-Notch style, Laydown style)

(We offer various PCD grades, edge preparations, corner radii, and chipbreaker options within these standard lines. Please contact us for specific availability.)

Custom Engineered PCD Inserts

When standard inserts cannot meet the demands of your unique application, our technical team excels at developing custom PCD solutions. We collaborate closely with you to design and manufacture inserts tailored for:

• Complex Part Geometries: Non-standard shapes, profiles, and clearance angles.
• Specialized Materials: Optimized PCD grades (varying diamond grain size, binder, and thickness) for challenging composites, ceramics, or specific alloys.
• Unique Edge Preparations: Custom hones, chamfers, or T-lands for enhanced edge strength or specific finish requirements.
• Advanced Chip Control: Integrated, custom-designed chipbreakers for effective chip management in difficult-to-chip materials or specific cutting conditions.
• Combination Tooling: Inserts designed for multi-functional tools performing several operations simultaneously.

Advanced Chipbreaker Technology for PCD

Effective chip control is vital for process security, operator safety, and surface integrity, especially in ductile non-ferrous materials. We offer PCD inserts featuring standard molded or ground chipbreakers and possess the expertise to engineer application-specific chipbreaker geometries that ensure consistent chip formation and evacuation.

Your Expert Partner in PCD Tooling

Our commitment extends beyond supplying inserts. We leverage deep application knowledge, state-of-the-art manufacturing, and rigorous quality control to deliver PCD tooling that provides exceptional value and performance. Rely on our expertise for:

• High-Quality Materials: Sourcing premium PCD blanks for consistent performance.
• Precision Manufacturing: Utilizing advanced laser cutting, grinding, and EDM processes.
• Application Support: Providing technical guidance to select the optimal grade, geometry, and cutting parameters.

Request a Quote or Technical Consultation

Ready to enhance your non-ferrous and abrasive material machining? Contact our expert team today to discuss your specific application, request a quote for standard PCD inserts, or initiate the design process for a custom tooling solution.