Polycrystalline Diamond (PCD) tools offer exceptional benefits for machining aluminum workpieces, including extended tool life and high metal removal rates. However, their initial cost can be higher, which may lead to increased processing expenses. Today’s aluminum materials have evolved significantly, and when machining various newly developed aluminum alloys—especially high-silicon composite materials—it’s crucial to carefully select the appropriate PCD tool grade and geometric parameters to optimize productivity and processing quality. Fortunately, due to market competition and advancements in manufacturing processes, the cost of PCD tools has decreased by over 50%, making them more accessible.
Key Features of PCD Tools
PCD composite inserts are created by sintering diamond and a catalyst under high temperature and pressure, resulting in a unique structure with interconnecting "bridges" of diamond particles. This process creates a catalyst island structure, akin to monolithic diamond materials. Unlike PCBN (Polycrystalline Cubic Boron Nitride), which lacks actual binding material between CBN particles, PCD features a coalescent structure where diamond particles are interconnected through lattice bridges.
PCD tool grades are categorized by the size of diamond particles. According to industry standards, fine, medium, and coarse PCD grades correspond to approximate particle sizes of 2 μm, 10 μm, and 25 μm, respectively. Coarse PCD grades exhibit greater strength and wear resistance, providing longer tool life during rough machining. However, the cutting edges of coarse PCD tools may not achieve the smooth surface finish attainable with fine PCD tools, which, while providing superior surface quality, tend to wear out more quickly.
PCD cutting tools are ideal for applications such as diamond saw blades, construction coring and drilling, edge-trimming diamond cutters, turning and milling inserts, and diamond drill bits for hole-drilling in composite materials and circuit boards.
Boreas produces PCD tools renowned for their outstanding physical properties and extensive application range, all while maintaining a competitive pricing structure. If you’re interested in enhancing your machining capabilities, Boreas is your premier choice for high-quality PCD tools that deliver performance and value.
China Polycrystalline Diamond Factory, Manufacturer | Boreas (boreasdia.com)