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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)

PCD insert shape D (55° Diamond)

PCD insert shape T (60° Triangle)

PCD insert shape V (35° Diamond)

PCD insert shape W (80° Hexagon)

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.

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.

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.

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.