|Blade model||Blade size|
MOOKTOOL Poly-crystalline diamond (PCD) tools are rapidly replacing carbide tools in many non-ferrous metal processing applications. If used properly, the PCD tools can maximize cost savings, superior machining precision and long life as well as some other characteristics.
PCD thermal conductivity coefficient is 700W / mk, which is 1.5 to 9 times more than carbide tool,even higher than CBN and copper, so the heat transfer of PCD tool is fast
PCD friction coefficient is typically only 0.1 to 0.3 and carbide friction coefficient is 0.4 to 1, so the PCD cutting tools can significantly reduce the cutting force;
PCD hardness up to 8000HV, which is about 8 to 12 times more than carbide tool.
Thermal expansion coefficient of PCD is only 0.9 * 10Ʌ-6 ~ 1.18 * 10Ʌ-6, equivalent to only 1/5 of carbide tool, therefore thermal deformation of PCD is small, and the processing precision is high.
The affinity between PCD tool and non-ferrous metals and non-metallic materials is very small, in the processing process cut chips are not easy to be bonded on the tip and forming the build-up edge.
PCD cutting tool wear resistance is 20 to 40 times higher than Carbide tool, which mainly processing non-ferrous metals, glass fibers, plastics and so on.
When cutting aluminum alloy, The roughing cutting speed of carbide cutting tools is about 120m / min, but PCD cutting tools can be up to about 360m / min even machining the high silicon aluminum alloy material. MOOKTOOL recommended use fine particles (or medium granule) PCD grade to machine the silicon-free and low-silicon aluminum alloys and adopt the coarse particles of PCD grade to machine high silicon aluminum alloy material. if milling workpiece surface can not meet the requirements, which can be modified the smaller size of the trimming blade to obtain the satisfactory surface finish.
The correct application of PCD tool is the precondition to obtain satisfactory processing effect. Although the specific reasons for the failure of the tool are different, but usually due to the use of the object or the incorrect use of the method. When ordering the PCD tool, the user should grasp the tool's adaptation range. For example, when using PCD tool processing the black metal parts (such as stainless steel), it will cause the PCD cutting tool wear quickly due to diamond easily with carbon steel chemical reaction, and therefore, the correct choice of hardened steel should be PCBN tools.
Generally speaking, in order to reduce the cutting force to prevent the BUE forming, PCD should adopt the tangent cutting angle. But in the processing of high silicon aluminum alloy (especially use PCD tools instead of carbide tool), The relief angle of PCD (such as 250) is better to choose slightly smaller than Carbide tools to improve the PCD Tool cutting performance against at the high silicon aluminum alloy. The Positive rake angle of PCD tool should be not too large, because the larger the angle of the tool before, the lower the cutting strength, in other words, the smaller the relief angle of PCD cutter, the higher the cutting edge strength. In order to, make the tool for the tangent angle cut the premise as far as possible to improve the strength of the cutting edge, MOOKTOOL welded the blade of negative rake angle CNMX on the PCD cutting tool position and forming the tangent angle cut, so that blade negative rake angle provides both high cutting edge strength, and the cutter does not affect the normal cutting. Preparation of PCD Tool cutting edge, do not need to do more process on diamond tool tip, for PCD milling cutter, can do slightly grinding on cutting edge, in addition to the cutting edge produces a certain axial inclination also helps to improve the cutting performance of PCD cutting tool.
|Material Science||cutting speed V£¨m/min)£©||Depth of cut ap(mm)||feed f(mm/rev)|
|Aluminum Alloy; aluminum, aluminum and aluminum casting molding||Rough turning 1000£3000||0.1£3.0||0.1£0.4|
|Finish turning 1000£3000||0.05£0.8||0.03£0.2|
|Aluminum with high silicon content||Rough turning 200£700||0.1£2.5||0.1-0.4|
|Finish turning 200£700||0.05£0.8||0.03-0.2|
|Copper alloy: brass, bronze, white tin, copper, zinc alloy, magnesium alloy||Rough turning 600£1000||0.5-2.0||0.1-0.4|
|Rough turning 700£1200||0.05-0.5||0.05-0.4|
|Cemented carbide with a maximum amount of no more than 15%||Rough turning 20£25||0.1£0.5||0.1£0.3|
|Finish turning 20£30||0.05£0.2||0.05£0.2|
|Hard rubber, glass, ceramics, graphite, all kinds of plastics, PVC, PA, PE, fiber reinforced plastics (GFK)||Rough turning 80£1000||1.0£2.0||0.1£0.4|
|Rough turning 800£1500||0.1£2.0||0.05£0.3|
1, the tool nose center cutting edge must be strictly aligned with the workpiece (less than 0.02mm from the center), if less than the workpiece center will cause the tool chipping, life reducing, bad roughness and tool vibration phenomenon; if higher the workpiece, it will appear tool vibration, bad workpiece surface , bad roughness,lower life,and cutting force increasing phenomenon , so plsmust be strictly adjust ment!
2, PCD cutting tool is hard and brittle, any low velocity impact and collision may cause damage, so please strictly in accordance with the recommendation of the processing parameters to use, strictly prohibited setting tool below the cutting speed, tool clamping and transfer are prohibited to touch foreign body, otherwise, it is easy to cause damage to the tool and can not be used.
3, PCD tool is only suitable for finish machining, more machining allowance to be caused the tool breakage or life reduced.
4, shall not be changed the tool body and tool head angle, size, etc., to avoid undermine the original design of the tool.
5, the tool must be installed properly, do not extend too long. (preferably to use machine with good rigidity).
6, intermittent processing should reduce the feed rate, improve the line speed, to ensure that the tool will not produce a strong clamping.
7, PCD cutting depth should not exceed the 3/4 of tool tip, otherwise please multiple processing.
8, the cutting tool with a blunt should put back the original box and timely grinding and replacement blade, otherwise it will appear parts roughness reduced, cause burr, tool head off, tool fracture, collapse edge phenomenon, and resulting in the scrap products; suggest to setting the certain tool life and force to the tool change.