With the continuous advancement of technology, market demands for high-performance mechanical products continue to rise.
To meet these demands, advanced materials such as ceramics, sapphire, carbon fiber composites, carbon/ceramic composites, titanium alloys, and high-temperature alloys are increasingly used across industries, including semiconductor, aerospace, medical, consumer electronics, and automotive sectors.
These materials offer high strength, hardness, toughness, wear resistance, and excellent corrosion resistance, making them ideal for challenging applications.
However, these advanced materials are notoriously difficult to machine, often causing issues like excessive tool wear, poor workpiece surface quality, and low processing efficiency.
To address these challenges, our team has leveraged years of expertise and innovation in high-performance tools to introduce the Integral PCD Tool Series, delivering nanometer-level precision machining.
Advantages of PCD Tools
Polycrystalline Diamond (PCD) is a composite material created by sintering diamond powder and a small amount of metal (such as cobalt) under high temperatures and pressure. This material offers high hardness, thermal conductivity, low friction, low thermal expansion, and strong adhesion resistance.
Integral PCD cutting tools are manufactured by welding PCD composite sheets onto carbide or steel bodies, making them particularly effective for machining hard, brittle materials, composites, and challenging metals. This tool series not only delivers higher machining accuracy and extended tool life but also helps customers improve efficiency and reduce production costs.
Key Applications of Integral PCD Tools
1. Silicon Carbide (HV2300) Machining – Achieving Mirror Finish
A standout product in the PCD tool series is the Integral PCD Micro-Edge Milling Cutter, ideal for high-gloss, high-precision machining of hard, brittle materials and composites.
This cutter offers a minimum blade diameter of 0.4mm and a maximum diameter of 45mm. Laser grooving technology ensures superior blade surface quality, with a minimum blade width of 5μm and up to 300 cutting edges.
When machining silicon carbide (HV2300), this tool performs milling rather than grinding, achieving a mirror finish with roughness ≤5nm.
2. High-Temperature Alloy Machining – High-Gloss Finish on End Surfaces
High-temperature alloys, known for their high hardness, strength, and low thermal conductivity, are typically challenging to machine, often resulting in high surface roughness.
Integral PCD micro-edge milling cutters have enabled customers to achieve efficient, high-quality finishing on both end faces and sides of high-temperature alloys, receiving positive feedback. In one case, a customer initially used diamond-coated tools, which failed to meet surface roughness requirements.
Switching to the PCD micro-edge cutter reduced end-face roughness (Sa) from 135nm to 45nm—a 67% improvement—and side roughness (Sa) from 1427nm to 289nm, a 79% reduction, achieving a high-gloss finish on both surfaces.
Key Benefits of Integral PCD Tools
- High Precision: Achieve nanometer-level precision, meeting rigorous standards in demanding applications.
- Extended Tool Life: The high hardness and wear resistance of PCD material significantly prolong tool life.
- Increased Efficiency: Minimize downtime and maintenance, boosting production efficiency.
- Superior Surface Quality: Advanced tool design provides excellent surface finishes, reducing the need for secondary processes.
Conclusion
The Integral PCD Tool Series is an exceptional solution for machining high-hardness, high-wear-resistant materials, providing customers with solutions to the challenges posed by advanced materials.
With superior precision and durability, PCD tools enhance processing quality and efficiency, proving ideal for meeting future high-complexity machining needs.
