PCD Tooling and their Effective Uses

by Saws and cutting Tools direct Saws and Cutting Tools Direct

The most complex stone on the planet, the diamond, is also the most abrasion-resistant. Due to this unique property, diamond, particularly synthetic diamonds like a polycrystalline diamond, is well suited for cutting tools. Polycrystalline diamond tools are known for their long cutting life, ability to cut at higher speeds, and superior performance when cutting nonferrous materials like aluminum and composites.

PCD is a strong material made up of a tungsten carbide substructure and diamond crystals that are randomly arranged. Because single diamond grains are connected, the product’s strength and shape are preserved. These synthetic diamonds are created in a lab using a high-temperature, high-pressure sintering technique that employs cobalt alloy to fill the gaps between PCD grains.

What are the advantages of PCD tooling that make them stand out?

The tool life of solid carbide tools is shorter, ranging from a few days to several weeks, depending on production levels. In contrast, PCD tooling is designed to endure months, resulting in less downtime. Because PCD machines offer more efficient workflows, fewer tool changes, planer knives, and faster cycle times, they are ideal for high-yield production facilities and smaller shops. M42 Bandsaw Blades When PCD tools are at their most efficient and effective, they can run up to 10 times faster than solid carbide tools. As a result, jobs are completed faster, resulting in shorter lead times and more finished work.

Secondary finishing techniques like grinding and deburring are costly, time-consuming, and energy-intensive. PCD tooling is more exact than carbide and high-speed steel (HSS). It can maintain its cutting edge and shape for more extended periods, allowing you to finish more components in less time while improving precision and quality. Because it could only be used on a limited range of materials, PCD tooling was long regarded as a specialty item. PCD tooling may now be used in various applications, including aluminum, composites, and abrasive polymers, thanks to advancements in production techniques and materials. PCD equipment can generate a high-quality surface finish without any additional processing. Producers can save time and money while maintaining the same level of quality as a consequence.

Conclusion

PCD tooling may be the way of the future for many industries because of these advantages. Production engineers will be able to save costs, shorten lead times, and make better things as PCD tooling becomes more adaptable to a broader range of materials. PCD comes in a variety of 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 saw blades increases tool performance by minimizing material buildup on the cutting surface (face) and lowering the amount of heat generated during the cut.