PCD (Polycrystalline Diamond) Inserts | Machenzzo

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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.

Aerospace Industry

Automotive Industry

PCD inserts are used to machine parts for engines, transmission systems, and suspension components in the automotive industry.

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.

Medical-Industry

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.

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