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Tipped pcd turning and milling inserts polycrystalline diamond inserts with brazed pcd cutting edges

Advantage of tipped pcd inserts over full faced pcd inserts is the lower cost, tipped insert is one use only economical type, it requires a carrier like tungsten carbide base as substrate for the insert, and substrate have a pocket that will accommodate and support the tip, the working tips are brazed to tungsten carbide base, 1~4 tips depends on different insert shapes, this braze joint of tipped pcd inserts represents the weak link not so good as full face pcd inserts, the maximum cutting depth is not more than 80% of the tip length, tipped pcd inserts could be used for fine to super fine precision machining, continous to interrupted machining, to obtain a good surface finish. As pcd is a polycrystalline form of diamond, so the cutting temperature is limited and could not exceed 700℃, also the work material has no affinity with carbon, pcd inserts are widely used for machining non ferrous metals of tungsten carbide, aluminum, copper, zinc; and non metals material of plastic, rubber, wood, ceramics.

There are different shapes of inserts available in the market. You should have detailed knowledge about all these shapes before you are going to buy. 1. C shape is the diamond shape (80 degree) 2. D Shape is also a Diamond shape (55 degree) 3. K Shape is a parallelogram in shape (55 degree) 4. R is for the round shape 5. S represents the square shape 6. T is for the triangle shape 7. V is another code for diamond shape (35 degree) 8. W represents the Hexagon (80 degree)

PCD insert shape C (80° diamond)

CCGW/CCMW0602 CCGW/CCMW09T3 CCGW/CCMW1204 CPGW/CPMW0602 CPGW/CPMW09T3 CCGT/CCMT0602 CCGT/CCMT09T3 CCGT/CCMT1204 CPGT/CPMT0602 CPGT/CPMT09T3

PCD insert shape D (55° Diamond)

DCGW/DCMW0702 DCGW/DCMW11T3 DPGW/DPMW0702 DPGW/DPMW11T3 DCGT/DCMT0702 DCGT/DCMT11T3 DPGT/DPMT0702 DPGT/DPMT11T3

PCD insert shape T (60° Triangle)

TCGW/TCMW0902 TCGW/TCMW1102 TCGW/TCMW16T3 TPGW/TPMW0902 TPGX/TPMX1103 TCGT/TCMT0902 TCGT/TCMT1102 TCGT/TCMT16T3 TPGT/TPMT0902

PCD insert shape V (35° Diamond)

VBGW/VBMW1604 VCGW/VCMW1103 VCGW/VCMW1604 VBGT/VBMT1604 VCGT/VCMT1103 VCGT/VCMT1604

PCD insert shape W (80° Hexagon)

WCGW/WCMW0402 WCGW/WCMW06T3 WCGT/WCMT0402 WCGT/WCMT06T3

superabrasives tooling tipped with synthetic polycrystalline diamond (PCD) has achieved a great reputation for productivity in machining nonferrous materials from 1970s, though tipped pcd inserts are more expensive than tungsten carbide inserts, inserts with pcd cutting edges have greatly increased the fine machining work parts, and the lifetime is about two hundred times than tungsten carbide inserts, clients can process thousands of work parts instead of hundreds without compensating for size offsetting before an insert replacement.

The pcd tipped inserts are mainly used for the turning and milling of the non-ferrous hard metals, These inserts are manufactured especially for different types of technologies and other advanced material processes. These are highly beneficial and have different characteristics and advantages. These are better and cheaper than that of full top surface pcd inserts and also offer a better surface finishing.

These tipped inserts are made of pure polycrystalline diamond and cannot be destroyed. It provides the best performance and offer hardness too. It also has a high wear resistant power with a long service life. They are also available in affordable prices and thus industries do not have to spend a lot over these inserts. It has a superior processing precision and with all these qualities and benefits, these inserts are grabbing a great position in market place worldwide.

WORK MATERIAL AND APPLICATION Work material Application Aluminum Automobile and motorcycle spare parts, engine, shell, bearing. Aircraft spare parts, shell, compression components. Precision mechanical spare parts, hydraulic machine. Aluminum alloy Cast Aluminum Copper Automobile, vehicles, ship spare parts, mandrel, gear, bearing parts. Electric machinery spare parts: electrical motor, commutator. General mechanical spare parts: bearings, screws. Copper alloy Casting copper alloy Cemented carbide Sintered tungsten carbide mold Non metals cemented Solid wood and man-made plywood, organic materials. Acrylic, reinforced synthetic resin, stone, ceramics, etc.

Recommended cutting condition Cutting material Cutting speed Vc (m/min) Feed f (mm/rev) Depth of cut ap (mm) PCD Aluminum and Aluminum alloy 200~3000 0.05~0.5 0.05~1.0 Non metals cemented 100~500 0.05~0.5 0.05~1.0 Tungsten carbide 20~30 0.05~0.2 0.05~0.2

pcd inserts with bigger diamond particles perform a greater abrasion resistance, but the cutting edge is rough. on the other hand, smaller diamond particles offer the insert with a sharper cutting edge, it will get a superior workpiece surface finish, but less lifetime.

Micro structure of PCD material PCD inserts cutting with/without chip breaker

PCD Grain size=5μ for turning of aluminium alloy with silicon content (Si<12%), the inserts are suitable for cutting graphite, carbon, plastic, rubber, rood, copper and bronze alloys, zinc. it provides a good surface finish, excellent wear resistance, medium impact strength.

PCD Grain size=25μ for rough to finish turning of aluminium with high silicon content (Si>12%), rough turning of highly abrasive composites, cemented tungsten carbide <12% cobalt, ceramics. it has high wear resistance and impact strength.

Excellent surface finish of fine grain size PCD grain size affects work piece surface roughness PCD materials wear resistance comparison in different grain size

Selecting the optimum grade of pcd tooling for a specific application is generally a function of surface finish requirements and tool life expectations. Material removal rates, tool geometries, and material characteristics also affect the relationship between machining productivity, tool life and surface finish.

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Source: http://www.pcd-insert.com/tipped_pcd_insert/tipped_polycrystalline_diamond_pcd_cutting_tool_inserts_for_turning_milling.html

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