PCD dies are ideal for long production runs and for drawing abrasive wire materials as they outlast TC, SSCD, and ND dies.
PCD dies to provide uniform hardness and extended wear resistance in all directions.
Specification: K01 K05 K10 K20 K30 K40
Application: wire drawing, steel drawing, etc.
Specification
PCD Drawing Dies What is a drawing die?
In metal pressure processing, the metal is forced through the die under the action of external force, so that the metal cross-sectional area is compressed and the required cross-sectional area shape and size are obtained. We call it a drawing die.
PCD Drawing Dies
PCD Drawing dies are ideal for long production runs and for drawing abrasive wire materials as they outlast TC, SSCD, and ND dies.
Polycrystalline diamond dies are available in various grain sizes, both in supported and unsupported configurations.
PCD dies to provide uniform hardness and extended wear resistance in all directions.
Wire drawing dies are commonly used to reduce the diameter of various ferrous and non-ferrous rods and wires. Applications include high, medium, and low voltage cables, automotive, medical wires, superconducting, bonding, and welding wires.
Advantages of PCD Drawing Dies
Long-lasting (outlasts TC and SSCD/ND dies)
Ideal for long production runs
Ideal for highly abrasive wire materials
The wire remains round, even with significant die-wear
Tailored to wire alloy
Features of PCD Drawing Dies
Usable with dry and wet draw
Available in any casing size
Various grain sizes are available
Dies available for high-temperature applications
Tight-tolerance dies available
PCD sintering drill bits products are suitable for different grades of aluminum alloys and CFRP/GFRP materials.
And can be used in abrasive materials in the automotive, aerospace and all composite material processing industries to meet the high quality requirements for drilling...
CFRP is notoriously difficult to machine without delamination, uncut fibers and fiber pullout.
Compared with traditional coated tools, even at higher cutting parameters, not only the process is more reliable but also the blade life is longer.
Using advanced PCD sintering technology to achieve a high degree of process reliability and stability.
The outlet of the processed hole has almost no breaks and burrs, and the surface quality of the hole wall is good; For composite materials processing, minimize the risk of delamination.
PCD sintering drill bits cutter body are made of fine-grained carbide material, PCD cutting edge is sharper, while bringing higher machining quality and longer tool life.
PDC cutter is mainly applicable for PDC drilling bit for drilling into soft and intermediate-hardness stratum.
Alias:
Polycrystalline Diamond Compact
PDC Inserts
Application:
Petroleum
Oil field PDC bits
Size:
0608, 0808, 1304, 1308, 1313, 1613, 1616, 1913, 1916
Shape:
Plain/flat, Round, Spherical/Dome, Conical etc.
The diamond drill bit is used in nearly all applications including geothermal energy drilling, mining, water well and natural gas drilling, and oil well drilling.
Total depths range from 100' to 20,000'.
Application of PDC cutter
PDC cutters are widely used for petroleum and oil field PDC bit, geological PDC exploration bits, gas exploration bits, PDC coal mining drill bits.
PDC is mainly applicable for PDC drilling bit for drilling into soft and intermediate-hardness stratum.
Advantages of PDC cutters
New cutting surfaces will appear during the course of abrasion, which keeps effective cutting rocks
High strength, high hardness and high wearing property of diamond layer as well as good self-sharpening
PDC drilling bit made of such PDC will break up rocks depending on shearing action when it works, which is more effective than crushing of rocks by roller conebit or plowing and grinding of rocks by diamond impregnated bit
The serrate structure combination between polycrystalline diamond layer and hard alloy substrate allows more fixed combination between the two layers and more impact resistance of the whole PDC.
Correct use of PDC drill bits
PDC bits work best in large sections of homogeneous soft to medium hard formations.
Not suitable for drilling gravel layer and soft and hard interlaced formation.
It adopts low drilling pressure, high speed, and large displacement for drilling, and the drill bit has a good effect.
Before the drill bit goes into the well, the bottom of the well should be cleaned to ensure that there are no metal falling objects.
When the drill bit just goes into the well, it is necessary to use a small WOB and low rotational speed to run in harmony, and resume normal drilling after the bottom hole is formed.
PDC drill bits are integral drill bits without any moving parts and are suitable for high-speed turbine drilling.
Solid cbn (cubic boron nitride) inserts for rough and finish machining
Model: SNGN, SCGN, CNGN, TNGN, DNGN, RNGN, RCGX, RCGV, etc
Applications of solid cbn: Brake disc, brake drum, pump parts, gears, valve, bearing, roller, engine cylinder head, cylinder sleeve, cylinder block, power...
Specification
Solid CBN Inserts are made of cubic boron nitride micro powder under the process of super high temperature and high press. The pcbn material is the hardest known material second only to synthetic diamond. PCBN inserts are made of CBN super hard material, have perfect impact and abrasion resistance performance. Rough turning and dry cutting application. The hard turning processing is considered as a better alternative to the conventional grinding process due to the possibility of operating in a single step that provides a surface finish as compared to the super finishing achieved in grinding process. More Superhard's solid cbn inserts for multiple machining requirements. Whatever your cutting application requires, solid cbn inserts provide the best in geometry, hardness and performance.
The Features of solid CBN inserts
- Solid cbn has stronger outstanding wear-resistance, toughness compared to ceramics. Therefore, it's a good solution for both roughing and high speed finishing of cast iron.
- Higher content CBN inserts
- Ideal for high feed and high depth of cut machining. For highly efficient machining at large depths of cutInserts made entirely of CBN do not limit the depth of cut as conventional brazed CBN tools do.
- To achieve the high speed and efficiency of CBN finishing but now also for roughing applications.
- Balance of wear and fracture resistance
- Strong corrosion resistance
- Good thermal stability
- Suitable for all kind of turning lathe and CNC turning center
Single Pass Diamond Honing Tool Description
MORE supplies diamond honing tools designed for your specific application. The single stroke honing tool is also known as a single pass honing tool that incorporates a super abrasive sleeve mounted on a tapered mandrel for precision bore sizing and finishing.
Each individual piece of this diamond tool is designed to be matched with corresponding honing machines.
According to different workpieces, customers can choose from our existing models of honing tools, or customize a new honing tool.
Electroplated and sintered diamond honing tools are divided into adjustable fixed honing tools and adjustable floating honing tools. The honing machine is a one-piece electroplated and sintered diamond tool with a single up and down stroke to grind away the excess.
Processing materials: mild steel, hardened steel, cast iron, copper, carbide, ceramics, glass, etc.
Electroplated diamond honing tools Features:
According to the different particle size of diamond, it can be used for rough honing, fine honing and fine grinding.
The superior diamond plating process ensures long tool life and low cost per part.
Improved abrasive sleeve design for chip quick removal.
Greater accuracy and increased production efficiencies.
Custom design to meet your specific requirement.
Capable of adapting to most honing machines.
Machinable diameter range: Customized according to machining workpiece drawings.
Electroplated diamond honing tools Application areas:
The products are suitable for honing inner hole of cylinder hole of refrigerator and air conditioner compressor, piston hole, nozzle oil pump, hydraulic valve, motorcycle, automobile engine cylinder block, gear, powder metallurgy parts, super hard parts, distribution valves, ABS, brake cylinder, supercharger, rocker arms, connecting rod, parking pawls, crankcase, sprockets, powdered metal components, ceramic components and so on.
Information to be confirmed before single-stroke diamond honing reamers are produced:
The name of the workpiece to be machined, the size of the hole to be machined, the depth of the hole, the material, the hardness, the honing allowance, and the roughness requirements
The information that needs to be confirmed to customize Honing rod:
1. Customers provide drawings, we produce according to the drawings. If there is none, we can give the customer drawings of approximate shape and size for reference, and let the customer confirm the specific information.
2. The link between the equipment and the honing reamer can be confirmed by sending pictures.
High Precision Single-Pass Honing Tools
Diameter Range: 4mm to 70mm
Honing Sleeve Types: Sintered Diamond, Electroplated Diamond
Used on Vertical Honing Machines for Progressive Honing
Adopted in automobiles, tractors, power machinery, construction machinery, refrigeration machinery, and the aerospace industry.
Specification
Single stroke honing is also called sequential honing or diamond hinge honing tool, it is a new process of micron precision machining, can process through hole, blind hole, keyway hole, step hole and other hole.
It is the engine injection pump, connecting rod, fork, hydraulic valve body, valve sleeve, air bearing, precision gear, die guide sleeve, air conditioner compressor main and auxiliary bearings, refrigerator compressor shaft hole (cylinder hole), piston, measurement ring gauge and other high-precision internal hole processing products commonly used technology. In recent years, single-stroke honing technology has been adopted in automobile, tractor, power machinery, construction machinery, refrigeration machinery and aerospace industry.
Advantages of single stroke diamond honing reamer
After honing, inner hole size consistency is high, cylindricity is very good.
â??Hinge honing has the advantages of high efficiency, good surface quality and high dimensional consistency.
Stable quality, high precision, long service life.
Single stroke tool, using imported abrasive, high cutting efficiency, fast processing and high precision, suitable for mass production.
The abrasive tools of single-stroke honing have a long service life and high efficiency in processing and production. They can be used in a variety of equipment, such as vertical drill, rotary drill, ordinary lathe, modular machine tool, press machine, vertical or horizontal honing machine tool, etc.
How to use the honing reamer
Put the hinged honing rod into the corresponding honing machine, from the first axis to the last axis, the outer diameter of the honing sleeve abrasive increases in turn, and the abrasive grain size also becomes finer. After the inner hole of the workpiece is honed from the first axis of the honing rod to the last axis, the hole diameter gradually increases, and the roughness gradually decreases. After the last knife, the part can reach the required size, roughness and Geometric Tolerances.
Turning and dressing straight type conventional abrasive wheels
Diamond size: 0.1 ct, 0.5 ct, 1 ct, 1.5 ct, 2 ct, 2.5 ct, 3.0 ct, etc
Diamond dressers for truing and dressing of conventional abrasive grinding wheels.
Use single/multiple natural diamond one-off dressers;
Suitable for various of cylindrical grinding machines, centerless grinding machines, surface grinding machines and special grinding wheels;
Specification
Single Point Diamond Dresser is made with natural diamond and synthetic materials like CVD, PCD and MCD, in various shapes shank for straight or form dressing.
Single point diamond dresser is used for dressing and turning straight type conventional abrasive wheels (dressing ceramic abrasive SG grinding wheels, simple profiles, thread and gear grinding).
The widely used in gear grinding, bearings, auto parts, textile machinery, aerospace and other fields.
Features of Single Point Diamond Dresserï¼?
High quality Diamonds.
Can be available in any Shank size on request.
Mounted on a shank by sintering and is used to true and dress grinding wheels by its sharp cutting edge in order to maintain their performance high for effective and high precision grinding work.
Available in shank sizes 1/4â??, 3/8â??, 7/16,â?? 1/2â?? and over all length 1-1/2â?? to 6â??
Ideal tool for dressing wheels for Surface Grinders, Universal Grinders, Cylindrical Grinders, centre less grinders etc.
Carat size available: 0.16, 0.25, 0.35, 0.50, 0.75, 1.00, 1.25, 1.50, 2.00, 2.50, 3.00, 3.50, 4.00, 5.00
Carat Sizes 1/4, 1/3, 1/2, 3/4, 1, 1-1/4, 1-1/2, 2, 2-1/2, 3, 3-1/2, 4 and 5
Also available Multi Point Diamond Dressers.
Indexable single point diamond dresser
Indexable tools are specifically designed to alleviate any misalignment issues and are the choice for CNC grinders.
Indexable single point dresser has a two-part construction with the head and shank as separate pieces.
After the initial installation, when the tool shank remains secure (and aligned) in the tool holder, operators only need simply turn the indexable head with a wrench.
Features of indexable single point diamond dresser:
* Easily turned without removing tool from the holder
* Long life, less downtime and increased productivity
* Excellent choice for regulating wheels
Product advantages:
high wear resistance, the service life of cemented carbide is 80-180 times
High grinding accuracy, up to micron level
High hardness, good wear resistance
It has good thermal conductivity
Application:
precision workpiece top car, top grinding processing use;
Supporting high-end precision testing equipment.
Specification
The top of the diamond is made of diamond polycrystalline material, which is inlaid on the top matrix by special technical means, and the top matrix is made of high strength steel.Through the production of high-end processing equipment, skilled high-end technical workers operation, precision detection means to ensure.Is a high precision high-tech content products.
Ceramic Tool Types
Ceramic grade tools are typically classified into three general categories: oxide, nitride, and matrix ceramics.
Oxide ceramics are alumina-based and are generally used in roughing and finishing applications of the cast and gray irons. Increasingly, oxide ceramics are being used in dry machining applications at high speeds. This is due to the advancements within materials science, including the incorporation of whisker-based materials.
Nitride ceramics exhibit extremely high fracture toughness and are used for roughing and semi-roughing of cast irons under harsh conditions, such as when there is considerable starting and stopping that would typically increase fracturing.
CMCs contain ceramics mixed with other hard materials like cemented and titanium carbides. They can also contain reinforcing whiskers and other materials to increase wear resistance and toughness under hot machining conditions. These are commonly referred to as SiC-whisker reinforced. Alumina reinforced with SiC whiskers is the toughest and most resistant to thermal shock of the oxide-based ceramics due to the extremely high tensile strength of the SiC whiskers. It offers the additional benefit of being able to be run without coolant, thus making dry machining a common application while also being able to offer an increase in machining rates up to 800%.
All ceramic cutting tools have excellent wear resistance at high cutting speeds.
There is a range of ceramic grades available for a variety of applications.
Oxide ceramics are aluminum oxide-based (Al2O3), with added zirconia (ZrO2) for crack inhibition. This generates a material that is chemically very stable but lacks thermal shock resistance.
(1) Mixed ceramics are particles reinforced through the addition of cubic carbides or carbonitrides (TiC, Ti(C, N)). This improves toughness and thermal conductivity.
(2) Whisker-reinforced ceramics use silicon carbide whiskers (Siew) to dramatically increase the toughness and enable the use of coolant. Whisker-reinforced ceramics are ideal for machining Ni-based alloys.
(3) Silicon nitride ceramics (Si3N4) represent another group of ceramic materials. Their elongated crystals form a self-reinforced material with high toughness. Silicon nitride grades are successful in gray cast iron, but a lack of chemical stability limits their use in other workpiece materials.
These benefits lead to increases in efficiency. For example, many machinists would slow cutting speed if temperatures were to approach maximum carbide limits. It is the opposite for ceramic tools, which excel in higher temperature conditions.
Application field:
3c field, aerospace, automotive industry, etc.
Machining Materials:
Non-ferrous metal materials, non-metal materials, composite materials, etc.
Advantageï¼?
High removal rates, Improved finished, Improved productivity, Reduced tooling cost.
Specification
More Super Hard Through huge R&D investment and close cooperation with customers, we can find the latest method to transform the cutting-edge characteristics of superhard materials into products with innovative performance, which have obvious performance and price advantages compared with competitors' products. Imported element 6, GE raw materials. Use high-precision peripheral grinder to produce high-quality PCD tools.
These PCD tools are widely used in high-silicon aluminum alloy, stone and other non-ferrous metals and non-metal processing. In traditional mechanical processing applications, not only the overall production cost is greatly reduced, but also the productivity and efficiency of the entire production operation are significantly improved, and at the same time, equipment investment is greatly reduced.
Introduction of honing stone
In principle, the perfect honing stone consists of three different main components, which offer the required cutting.
Abrasive
The abrasive is the most important component of each honing stone. Synthetic diamonds or cubic boron nitride (CBN) in various grit sizes are used.
Bond
The second component is the metal bonding which is responsible for the proper adhesion of the abrasive crystals warranting excellent wear performance.
Steel Blank or Carrier
The copper-plated steel blank is the third and last component and is the support material of each honing stone in a drawn, galvanized form.
The abrasive and the bond are weighed, mixed, and proportioned according to exactly define operation plans. The premixed portions are then filled into prepared sintering molds and fitted with the appropriate steel blanks. After this, all three elements are sintered under high temperatures. During the sintering process, an abrasive layer develops.
Applications of diamond and cbn honing stone
materials of workpiece: carbide,glass and ceramic,cast iron,alloy steel,tool steel,die steel,hardened steel copper,aluminum alloy and other abrasive resistant materials.
Applicable area:fine grinding engine pump body,hydraulic cylinder bore,hydraulic pump inner bore,cylinder block,valve,oil cylinder nozzle,the inner surface of the spline bore and cylinder hole and blind hole of other series.
Applicable honing machine:sunnen,nagel,belden,accucut,engis,and other types of high-production honing equipment.
Enables highspeed machining while maintaining longer tool life
Provides consistent products simplified quality control and lower cost
Maximum stability
Maximum economy
Maximum feedspeed
Suitable for general and optimized final machining
PCD MICRO DRILL SLOT STRUCTURE AND DRILL TIP
1. The grinding groove is smooth and the chip removal is excellent;
2. The edge surface is polished and the main edge is sharp;
3. The tip rotates stably and the hole position is accurate
PCD MICRO DRILLS FEATURES
1. PCD micro drill has characteristics of high hardness, wear resistance, and relatively long service life compared with traditional alloy microdrill;
2. PCD micro drill is widely used in addition to processing metal materials, and can also be used for inorganic non-metallic material processing, with high processing precision;
3. PCD micro drill, compared with traditional alloy micro drill, can process hole walls with better quality.
Applications of soldering brazed PCBN inserts:
The idea for machining hard ferrous metals, such as hardened steels, and gray cast iron.
Features of soldering brazed PCBN inserts:
â?¶High chemical resistance stability
â?¶High hardness and abrasive resistance
â?¶Strong impact resistance
â?¶Good fracture resistance
â?¶High working efficiency
â?¶Dry cutting
Specification
Description of soldering brazed PCBN inserts:
PCBN cutting inserts are welded directly onto the blade base to form a growing, super-strong structure, without the risk of layering or cracking.
Applications of soldering brazed PCBN inserts:
The idea for machining hard ferrous metals, such as hardened steels, and gray cast iron.
PCBN inserts are widely used to machine brake discs, engine cylinder liners, engine blocks, break drumsticks, valve seats & guides, gears, and mold, etc.
The mono-crystal diamond tools can obtain excellent cutting edge through grinding.The surface finish of single crystal diamond tool can reach more than 0.01micron (Ra < 0.1 um)
The world's top brands of raw materials: E6 single crystal diamond
Application industries: optical lenses, 3C, medical contact lenses, electronic, jewelry, watch marking and automotive industry, etc
Types Of Mono Crystal Diamond Cutting Tools
Depending on the equipment (CNC machine tools, CNC machining centers, etc.) and cutting processes used in different working conditions, single crystal tools can be welded on different tool bodies as required to make different cutting tools. Common types of single crystal toolsï¼?
Single crystal diamond inserts, Non standard Single crystal diamond turning tools, Mono crystal diamond milling tools, Mono crystal chamfering cutters, MCD grooving cutters, Single crystal ball milling cutters, monocrystalline diamond end mill, etc
MCD non-standard square bar type turning tools
- Suitable for turning non-ferrous metals such as copper and aluminum. The surface roughness after processing can reach Rz0.1~0.05�¼m, and the cutting depth during processing does not exceed 0.05mm
MCD mono crystal diamond Arc cutting tools
- Mono crystal diamond tool is suitable for the forming and processing of non-ferrous metals such as copper and aluminum. The size of the arc is designed according to the requirements of the workpiece.
MCD Non-standard integrated top and bottom chamfering cutting tools
- The tool has two cutting edges, and one tool can realize up and down chamfering without changing the tool, which is very cost-effective
Application of MCD non-standrad chamfering tool
- Chamfering of the outer frame of non-ferrous metals such as copper, aluminum, etc.
- The peripheral chamfering of mobile phone shell parts.
- Reasonable design and speed feed can eliminate the residual tool marks in the processing, and truly achieve the mirror surface of the processing surface effect
- The grain processing efficiency is higher, especially the mosaic welding, the speed can reach 70,000 revolutions/min, and the feed can reach 4000 mm/min, but it is inevitable that there will be residual tool marks in the processing.
Specification
Applications of PCD boring tools:
PCD boring tools are used for machining various of tungsten carbide rollers. PCD tips for carbide roller notching.
Advantages of PCD boring tools:
high abrasive resistance and thermal conductivity
good surface finish
Long service life. The service life is 20-30 times more than carbide boring tools.
PCD inserts are mostly used in high, medium and low silicon content aluminum alloys, graphite, metal matrix composites, carbon fiber composites, titanium alloys, aluminum alloy ultra-finishing industries, aviation and auto parts, etc. In traditional machining applications, it not only greatly reduces the overall production cost, but also significantly improves the productivity and efficiency of the entire production operation, while greatly reducing equipment investment.
PCD boring tools Application range
Rollã??Air Conditioning Compressor Partsã??Slewing supportã??Gear shaftã??Bearingã??Cylinderã??Cylinder linerã??Hub unit bearingã??Brake drumã??Brake disc.
Why Choose Our PCD Boring Tools
1. The raw material is excellent, and it is processed and sharpened by the element six PCD composite sheet.
2. Fine cutting edge, the hardness of diamond is about 8000HV, and the hardness is 10 times that of alloy. It has the advantages of low friction coefficient, high hardness and long service life. It can process a higher finish than conventional tools while reducing costs.
3. High-precision dimensions, tolerances of blade angle, blade tip, length, and equal division are strictly controlled within the tolerance of 0.02MM to ensure the stability of the life of each blade.
4. Complete specifications, various specifications and models can be produced, customized production according to the customer's use size, the manufacturer's supply makes you more assured.
Performance advantages of PCD/PCBN milling cutters
With ultra-high hardness and super wear resistance;
Stable performance and long tool life;
High processing efficiency and low cost;
High surface finish can be obtained;
High conductivity, good toughness.
Forming slot milling cutters have been successfully used in slot milling.
Multiple slots can be formed and milled at one time, which reduces the use of tools and the number of tool changes, and greatly improves the processing efficiency.
The water outlet design in the tool center can effectively reduce the processing heat in the cutting area, reduce tool wear and make the tool have a longer processing life.
PCD universal milling cutter, suitable for processing aluminum and aluminum alloys, copper and copper alloys and other non-ferrous metals, glass fiber and metal composite materials, glass, engineering ceramics, engineering plastics, and milling of materials such as stone and wood.
Suitable for high-efficiency Plunge milling, side milling, slot milling, contour milling, and spiral interpolation milling.
PCD/PCBN milling cutters features
The cutting edge adopts laser technology, the cutting edge is sharp, and the cutting is light and suitable for high-speed occasions.
PCD of medium grain size has both abrasion resistance and chipping resistance, and excellent overall performance.
Diameters of the same specification, different cutting edge lengths.
The cutting edge over-center design can be used for axial feed milling similar to drilling.
Optimize the groove shape to achieve a higher dynamic balance level.
The small R angle and chamfering of the cutting edge effectively increase the durability of the tool.
There are many classification methods of rolls,
- The material of the roller have : cast steel roller, case iron roller, forged roller.
- Product type, there are strip steel rolls, section steel rolls, wire rod rolls
- Position of the rolls in the rolling mill series, there are billet rolls, rough rolls, finishing rolls, etc.
- Product function, there are scale-breaking rollers, perforated rollers, leveling rollers, etc.
- Product material, there are hot rolls, cold rolls, etc.
- Type of rolling mill, it is divided into flat rolls and grooved rolls (it is used for rolling large, medium and small sections, wire rods and blooming billets. Grooves are engraved on the roll surface to shape the rolling stock), special roll
When processing mill rolls, especially processing large scale steel iron roll, it often has irregular surface, sand inclusion, holes and other problems. In order to solve the above problems we should choose What PCD and PCBN Inserts for Turning Rolls ?
- The tools materials for machining rolls include pcd inserts, pcbn cutting tools and solid cbn inserts, etc
- Solid CBN Insert is the hardest tool material for the processing ferrous metal materials and is the preferred tool for heavy duty cutting rolls. The high hardness rolls, Moresuperhard recommend the Solid CBN inserts which can be used for large margin cutting. Compared with the carbide cutting tools, the Solid CBN insert has performance stable, good production efficiency, and low production costs. Tungsten carbide ring is also called tungsten carbide alloy roll ring ( WC rolls or TC rolls), we process them with CBN and PCD Tools .
- Normally, CBN Inserts are generally used for rough turning tungsten carbide rolls which hardness â?¤ HRA88. PCD Tools are mostly used for finish turning cylinder, chamfering and engraving.
Types of cbn inserts: soldering compound inserts / solid cbn inserts
Applications of pcbn inserts: Rough and finish machining gray iron, alloy cast iron, hardened steel, brake drums, flywheels, brake discs, mining machinery, electrical equipemnt, machine tools, etc
Model cbn inserts: CCGW, TCGW, CNGA, TNGA, DCGW, RCGX
Specification
The hardness of cubic boron nitride (CBN) is second only to PCD and single crystal diamond. It can still maintain the hardness of cemented carbide at 25 degrees Celsius at a high temperature of 1000 degrees Celsius. The high strength of CBN comes from its intercrystalline bonds. Equipped with a hardness alloy matrix with very good hardness and toughness, the tools made with it can withstand great cutting forces when deep cutting materials with high hardness and high toughness. The intergranular bond also provides acceptable impact strength. This is very necessary when cutting continuous and discontinuous sections.
Applications of CBN inserts
Processing materialsï¼?such as cold work tool steel, hot work tool steel, high speed steel, bearing steel, hardened steel, powder smelting steel, powder smelting metal,martensitic stainless steel ect.
Processing fields: Rough and finish machining gray iron, alloy cast iron, hardened steel, brake drums, flywheels, brake discs, mining machinery, electrical equipemnt, medical, aviation manufacturing, machine tools, etc
Body material: Carbide
Blade material: PCD (polycrystalline diamond)
Specifications: 20~50 blades/non-standard customization
Processing materials: glass, ceramics, graphite, silicon carbide, titanium alloy, carbide
Application areas: glass contour molding, ceramic watch cases, graphite molds, and other hard and brittle materials
Specification
The PCD micro-edge cutting tool can process brittle and hard materials such as silicon aluminum, silicon carbide, graphite, carbon fiber, sapphire, ceramics, and tungsten steel, covering various high-tech and industrial application fields, with a surface roughness of Raï¼?0.08�¼m. Suitable for finishing workpieces made of titanium alloy or aluminum alloy, etc., and can eliminate vertical cutter marks left by milling cutter processing.
PCD micro-edge cutting tools can play an important role in processing in these fields, especially when facing the processing of brittle and hard materials. In these fields, the pursuit of high precision in material processing, long tool life, and high efficiency are key.
The following are the main application areas and processing material characteristics and advantages of PCD micro-edge cutting tools:
Silicon Aluminum and Silicon Carbide
Material Characteristics:
Silicon Aluminum Alloy: Commonly used in semiconductor devices and power electronics, this material is characterized by high hardness, with silicon particles reaching up to 1000 HV. Challenges include rapid tool wear, the formation of built-up edges, and difficulties in achieving desired surface roughness.
Silicon Carbide: With a Mohs hardness of 9.5, second only to diamond, silicon carbide is both extremely hard and brittle, making it prone to cracking during machining.
Advantages of PCD Tools:
PCD micro-edge cutting tools, with their diamond-welded heads, offer unparalleled hardness, wear resistance, and low friction. These attributes make them the ideal choice for processing silicon aluminum and silicon carbide, outperforming standard PCD tools by offering superior wear resistance and precision.
Application industry: 3C, automotive, aerospace, etc.
Application materials: non-ferrous metals such as aluminum, magnesium, titanium, silicon; fiber materials, insulating materials, plastics, composite materials, etc.
Specification
Performance advantages of PCD/PCBN milling cutters
With ultra-high hardness and super wear resistance;
Stable performance and long tool life;
High processing efficiency and low cost;
High surface finish can be obtained;
High conductivity, good toughness.
Forming slot milling cutters have been successfully used in slot milling.
Multiple slots can be formed and milled at one time, which reduces the use of tools and the number of tool changes, and greatly improves the processing efficiency.
The water outlet design in the tool center can effectively reduce the processing heat in the cutting area, reduce tool wear and make the tool have a longer processing life.
PCD universal milling cutter, suitable for processing aluminum and aluminum alloys, copper and copper alloys and other non-ferrous metals, glass fiber and metal composite materials, glass, engineering ceramics, engineering plastics, and milling of materials such as stone and wood.
Suitable for high-efficiency Plunge milling, side milling, slot milling, contour milling, and spiral interpolation milling.
PCD/PCBN milling cutters features
The cutting edge adopts laser technology, the cutting edge is sharp, and the cutting is light and suitable for high-speed occasions.
PCD of medium grain size has both abrasion resistance and chipping resistance, and excellent overall performance.
Diameters of the same specification, different cutting edge lengths.
The cutting edge over-center design can be used for axial feed milling similar to drilling.
Optimize the groove shape to achieve a higher dynamic balance level.
The small R angle and chamfering of the cutting edge effectively increase the durability of the tool.
Processing Part: Aluminum alloy wheel hubs for car, Aluminum Alloy Outer Circle, Head Face
Processing Way: Turning, Semi-Fishing, Fishing
Characters: PCD Turing Tools Have Long Service Life, High Efficiency And Work Pieces Have Higher Brightness Etc.
During the wheel hub machining process, uses the PCD wheel hub tool for repairing and refurbishing the aluminum alloy wheel hub rim.
Specification
Application of PCD wheel hub turning tools:
The PCD wheel hub tools are used for turning and finishing aluminum alloy wheel hub rims for cars.
Advantages of PCD tools for wheel hub cutting:
The tool bits of the PCD wheel hub turning tools use PCD & PCBN blanks by E6. The cutter arbor uses high-quality tungsten carbide and tool steel
Advanced Welding Technology To Ensure PCD turning tools No Turning, No Welding Off, No Carbonization, Long Life
Welded Integral Hub Tools with Good Tool Rigidity, Good Shock Resistance, Stable Performance, And Large Feed
It Is An Aluminum Car Wheel, Motorcycle Aluminum Wheel Hub, Electric Vehicle Aluminum Wheel Hub The Most Commonly Used Diamond Blade For Fine Turning.
What are PCD saw blades?
PCD Blades are blades for circular saws but compared to a standard circular saw blade where the teeth are tungsten carbide tipped, PCD blades have teeth made of Polycrystalline Diamond.
What is a polycrystalline diamond?
Diamond is the hardest material in nature and is the most resistant to abrasion.
Polycrystalline Diamond (PCD) is an artificial diamond produced in a laboratory through a sintering process. It is an extremely resilient material where diamond crystals are bonded to a base material of tungsten carbide.
During the sintering process, the spaces between the PCD grains are filled with a cobalt alloy and the single diamond grains bond to each other.
This results in a material that matches no other in terms of toughness, durability and resistance, making polycrystalline diamond an excellent cutting material and perfect for use in cutting tools especially where the material is particularly abrasive. It also contributes to the diamond tool having a longer cutting lifetime.
Diamond-tipped saw blades are an excellent choice when cutting larger volumes of homogenous material.
In particular, a polycrystalline diamond tipped (PCD) blade will excel in applications such as cutting melamine and HPL coated panel products, solid surface materials such as Corian, cement fiber board panels, and fiberglass, among others, which are all very hard on conventional carbide-cutting tools.
The PCD saw blade is used for cutting and grooving non-metallic materials, nonferrous materials, the particleboard woodworking industry, and the ultra-precision processing industry.
Posalux Diamond Tools is most commonly used for mirror bright cutting surface treatment of non-ferrous metal materials such as gold, silver and aluminum.
Can be installed on diamond faceting machines, CNC machine tools, lathes and other equipment to perform bright cutting and faceting on bracelets, rings, spheres, chains, pendants, etc.
Posalux Diamond Tools Features:
1. High finish processing: much higher than the hardness of cemented carbide, high dimensional accuracy, and mirror effect;
2. Strong wear resistance: strong impact toughness and fracture resistance, high metal cutting rate, and the cutting blade will not be broken during the interrupted cutting process with a heavy load;
3. Stable performance: the blade is made by precision machine grinding, is sharp and durable, and has a long service life;
4. Nano-coating: Improve the hardness and service life of the tool, increase the smoothness of the surface, beautiful and durable.
[Processing steps]: Inner hole/outer surface turning
[Tool holder type]: Upper pressure type C turning tool
[Outer surface turning tool square size]: 20*20, 25*25, 32*32, 40*40
What Are Tungsten Carbide Inserts?
Tungsten carbide inserts are cutting tools made from a composite material consisting primarily of tungsten and cobalt. Known for their exceptional hardness, wear resistance, and thermal stability, these inserts are essential in modern industrial manufacturing processes, enabling high-precision cutting and machining.
Applications of Tungsten Carbide Inserts
Tungsten carbide inserts are widely used across various industries, including:
Automotive Industry:
- Precision machining of engine components, axles, and transmissions.
Aerospace Industry:
- Cutting high-temperature alloys and titanium alloys for engine parts and structural components.
Mold Manufacturing:
- Processing hardened steel and die cavities in mold making.
General Machinery:
- Turning, milling, drilling, and boring for diverse mechanical parts.
Energy Sector:
- Machining wind turbine blades, oil pipelines, and drill bits.
Materials Processed with Tungsten Carbide Inserts
Tungsten carbide inserts are suitable for machining a wide range of materials, such as:
- Steel Materials: Carbon steel, alloy steel, stainless steel, etc.
- Cast Iron: Gray cast iron, ductile iron, etc.
- Non-Ferrous Metals: Aluminum alloys, copper alloys, magnesium alloys, etc.
- Difficult-to-Machine Materials: Titanium alloys, superalloys, composites, etc.
Advantages and Features of Tungsten Carbide Inserts
High Hardness and Wear Resistance:
- Retain sharp cutting edges under high-speed and high-temperature conditions.
Excellent Thermal Stability:
- Work efficiently at temperatures up to 800-1000�°C, ideal for machining hard materials.
High Cutting Efficiency:
- Enable faster machining, reducing production time and costs.
Versatility:
- Available in various geometries, coatings, and grades to meet diverse machining requirements.
Extended Tool Life:
- Resistant to wear, minimizing replacement frequency and ensuring stable operations.
