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   DR-PCD Application Examples
    PCD - Non Ferrous machining

 

    Component:
    Machine Tool:
    Material:
    Operation:
    Depth of Cut:
    Insert:
    Surface Speed:
    Feed Rate:
    Surface Finish:
    Tool Life:
    Comments:
Gear box casing
13% Silicon Aluminium
Toyoda Machining Centre
Face Milling
Typically 1.0 mm
SPKW 120404F EDR DR-PCD
800 m/min (2650 ft/min)
0.1 mm/rev/ tooth (0.004/rev/ tooth)
0.8 micron Ra
6 months and still cutting
Axially adjustable cutter required to give best results

 

 

    Component:
    Machine Tool:
    Material:
    Operation:
    Depth of Cut:
    Insert:
    Surface Speed:
    Feed Rate:
    Surface Finish:
    Tool Life:
    Comments:
Door Handle
Hard Brass
Hardinge  Conquest SP T42 CNC Lathe
Profiling
Typically 0.25 mm  (0.01)
VCMW 160404F DR-PCD
300 m/min (1000 ft/min)
0.05 mm/rev  (0.002/rev
0.4 micron Ra
Thousands of components
Cosmetically superior finish

 

 

    Component:
    Machine Tool:
    Material:
    Operation:
    Depth of Cut:
    Insert:
    Surface Speed:
    Feed Rate:
    Surface Finish:
    Tool Life:
    Comments:
Surface plate
Granite
Centre Lathe
Facing
Typically 0.5 mm  (0.02)
RNMN 090300F DR-PCD
60 m/min (200 ft/min)
0.1 mm/rev  (0.004/rev)
N/A
15 minutes contact
Good enough to go to lapping

 

    Component:
    Machine Tool:
    Material:
    Operation:
    Depth of Cut:
    Insert:
    Surface Speed:
    Feed Rate:
 
    Surface Finish:
    Tool Life:
    Comments:
Brake Disc
Metal Matrix Composite
Mori Seiki SL25 CNC Lathe
Facing
Typically 0.5 mm  (0.02)
RNMN 090300F DR-PCD roughing CNMA 120408F DR-PCD finishing
300 m/min (1000 ft/min)
0.3 mm/rev (0.012/rev) roughing - 0.2 mm/rev (0.008/rev) finishing
1.6 microns Ra
15 minutes contact
Extremely abrasive material 20% Silicon

 

 

    Component:
    Machine Tool:
    Material:
    Operation:
    Depth of Cut:
    Insert:
    Surface Speed:
    Feed Rate:
    Surface Finish:
    Tool Life:
    Comments:
Body Scanner ring
Glass Reinforced Plastic
DSG Centre Lathe
Turning
Typically 1.5 mm  (0.06)
CNMA 120408F DR-PCD
200 m/min (660 ft/min)
0.2 mm/rev  (0.008/rev)  
N/A
35 minutes contact
Extremely abrasive material 25% glass

 

    Component:
    Machine Tool:
    Material:
    Operation:
    Depth of Cut:
    Insert:
    Surface Speed:
    Feed Rate:
    Surface Finish:
    Tool Life:
    Comments:
Aircraft Control Surface
Carbon Fibre reinforced  Composite
Wadkin Routing Machine
Trimming around form
Variable
Brazed 16 mm Slot Drill (2 Flute )
200 m/min (660 ft/min)
0.1 mm/rev / Tooth  (0.004/rev / tooth)  
N/A
45 minutes contact
Extremely abrasive material

 

    Component:
    Machine Tool:
    Material:
    Operation:
    Depth of Cut:
    Insert:
    Surface Speed:
    Feed Rate:
    Surface Finish:
    Tool Life:
    Comments:
Mould Tool
Graphite
Centre Lathe
Turning
Variable
VCMW 160404F DR-PCD
As fast as possible
0.1 mm/rev (0.004/ rev)  
N/A
30 times Tungsten Carbide
Extremely abrasive material

    Component:
    Machine Tool:
    Material:
    Operation:
    Depth of Cut:
    Insert:
    Surface Speed:
    Feed Rate:
    Surface Finish:
    Tool Life:
    Comments:
Die Blank
Unfired Tungsten Carbide
Centre Lathe
Turning
Variable
DCMW 11T304F DR-PCD
As fast as possible
0.1 mm/rev (0.004/ rev)  
N/A
100 times Tungsten Carbide
Extremely abrasive material

    Component:
    Machine Tool:
    Material:
    Operation:
    Depth of Cut:
    Insert:
    Surface Speed:
    Feed Rate:
    Surface Finish:
    Tool Life:
    Comments:
Kitchen Cupboard Door
Medium Density Fibreboard (MDF)
Wadkin Routing Machine
Producing raised centre panel
10 mm
Form Router (2 flute) dynamically balanced to protect spindle
As fast as possible
0.1 mm/rev/tooth (0.004/ rev / tooth)  
N/A but surface must be suitable for coating
100 times Tungsten Carbide
Extremely abrasive material

 

    Component:
    Machine Tool:
    Material:
    Operation:
    Depth of Cut:
    Insert:
    Surface Speed:
    Feed Rate:
    Surface Finish:
    Tool Life:
    Comments:
Turbocharger rotor
6% Silicon Aluminium
Okuma LCS 10 CNC Lathe
Trimming rotor  vanes
Variable
DCMW 11T308F DR-PCD
500 m/min
0.1 mm/rev/tooth (0.004/ rev / tooth)  
Minimum burring
100 times Tungsten Carbide
The edge retention of PCD allows continuous burr free Production

    Component:
    Machine Tool:
    Material:
    Operation:
    Depth of Cut:
    Insert:
    Surface Speed:
    Feed Rate:
    Surface Finish:
    Tool Life:
    Comments:
Lens for safety glasses
Polycarbonate
Special Purpose
Profiling lens to fit frame
Variable
Special 4 flute cutter
250 m/min
0.1 mm/rev/tooth (0.004/ rev / tooth)  
N/A
100 times Tungsten Carbide
Problem free automatic production

 

 

 

 

 

 

David Richards Engineering 2013