Polycrystalline Diamond (PCD) inserts are synthetic diamond inserts used in cutting and drilling tools. In this guide, we discuss the many advantages of PCD inserts, the different types available, and how to care for them to extend their service life.
What are PCD Inserts ?
PCD inserts consist of a layer of diamond particles fused onto a tungsten carbide substrate using a high-temperature, high-pressure process. These inserts are exceptionally hard and durable, making them ideal for use in machining applications for non-ferrous metals, plastics, and composites.
Advantages of PCD Inserts
Enhanced Performance
PCD inserts have high wear resistance and low friction characteristics, which help reduce machining cycle times and improve production efficiency.
Improved Precision
PCD inserts allow for tight tolerances and high surface finishes. Their predictable wear patterns ensure consistent performance throughout their service life.
Versatility
PCD inserts can be used in a variety of machining applications, including turning, milling, and drilling. They are also ideal for finishing operations in aerospace, automotive, and medical industries.
Features of PCD Inserts
|
Material |
Diamond particles (synthetic) |
|
Substrate |
Tungsten Carbide |
|
Geometry |
Round, Square, Triangle |
|
Coating |
None or TiN |
|
Insert type |
Positive or Negative rake angle |
Applications of PCD Inserts
Aerospace Industry
PCD inserts are used to machine components for the aerospace industry, including engine casings, filters, and structural components.
Automotive Industry
PCD inserts are used to machine parts for engines, transmission systems, and suspension components in the automotive industry.
Medical Industry
PCD inserts are used to machine implants, surgical tools, and components used in medical devices due to their precision and biocompatibility.
Types of PCD Inserts
Full-face Inserts
The diamond layer covers the entire face of the PCD insert. These inserts offer high wear resistance and are ideal for finishing operations.
Top Brazed Inserts
Diamond grains are brazed only on the top half of the insert. This design allows for a larger diamond volume and better heat dissipation, making them ideal for roughing applications.
Segmented Inserts
These inserts have diamond segments brazed onto the substrate, allowing for more customization in terms of geometry and size. They are ideal for profiling and contoured machining operations.
Care and Maintenance of PCD Inserts
To increase the lifespan of PCD inserts, it is important to store them in a dry and clean environment, verify proper coolant flow, and regularly inspect them for signs of damage or wear. PCD inserts can also be reconditioned to recover their original performance with specialized services.
Conclusion
PCD inserts price offer exceptional advantages over traditional cutting tools for certain applications. Their high wear resistance, low friction, and versatility make them a popular choice for industries such as aerospace, automotive, and medical. To maintain their performance and extend their service life, proper care and maintenance are essential.
