Everything you need to know about PCD Tooling

by Saws and cutting Tools direct Saws and Cutting Tools Direct

Diamond is the world’s hardest substance, and as a result, it is the most abrasion-resistant. Diamond, particularly synthetic diamonds like a polycrystalline diamond, is highly suited for use in cutting tools due to this unique characteristic.

Polycrystalline diamond tools are known for their long cutting life, ability to cut at faster speeds, and exceptional performance when working with nonferrous materials such as aluminum and composites.

What is polycrystalline diamond?

Polycrystalline diamond (PCD) is a strong material made up of a tungsten carbide sub-stratum and diamond crystals that are randomly oriented. These synthetic diamonds are made in a laboratory using a high-temperature, high-pressure sintering method that uses a cobalt alloy to bridge the gaps between PCD grains because single diamond grains are bonded, an exceptionally robust product retains its strength and shape.

Benefits of polycrystalline diamond

• Solid carbide tools have a shorter life, ranging from a few days to a few weeks, depending on production levels. In contrast, PCD tooling is designed to endure months, resulting in less downtime. Due to more efficient workflows, fewer tool changes, planer knives, and shorter cycle durations, PCD tools are ideal for high-yield production facilities and smaller shops.

• PCD tools can run up to ten times faster than solid carbide tools when they are at their most efficient and effective M42 Bandsaw Blades. As a result, jobs are done faster, leading to shorter lead times and more work accomplished.

• Grinding and deburring are secondary finishing processes that take a long time and cost a lot of money, effort, and energy. PCD tooling is more precise than carbide and high-speed steel (HSS) tooling, and it can hold its cutting edge and form for longer, allowing you to finish more components in less time while enhancing precision and quality.

• PCD tooling was formerly a specialty item because it could only be used on a limited variety of materials. Thanks to production techniques and materials developments, PCD tooling may now be used in various applications, including aluminum, composites, and abrasive polymers.

• Surface Finish: PCD equipment can generate a high-quality surface finish without additional processing. Producers can save time and money while maintaining the same level of quality as a consequence.

PCD tooling can be the future for many manufacturers because of these five advantages. PCD tooling will enable production engineers to lower costs, shorten lead times, and deliver better goods as it becomes more adaptable to a broader range of materials.

PCD comes in a variety of various quality levels. Standard quality grades with varied grain sizes are offered for most machine applications. Coarser grain or a “polished” tip may be used in more demanding situations. Polished PCD enhances tool performance by reducing material collection on the cutting surface (face) by creating less heat in the cut.