Halnn PCD Inserts_News_Halnn superhard materials Co.,Ltd

Part 1 What is PCD Insert?

PCD Insert is a type of super hard materials which made of tungsten carbide body together with PCD Blank (Polycrystalline Diamond) through high temperature and high pressure. PCD Blank become PCD Insert after a series of process: cutting, brazing, tip grinding, inspecting.

Part 2 PCD Inserts Types

PCD Inserts can be divided into the following types: ISO PCD Inserts, PCD Milling Inserts, Chip-breaker PCD Inserts, PCD Grooving Inserts. All types can be made as the customers’ requirements.
(1) ISO PCD Inserts
It usually belong to indexable CNC Inserts as ISO Models, which can be used with same holder with carbide inserts, such as CCGW09T304. It usually has 1 cutting tip, can be used for turning cylinder, inner bore, end surface, ect.
(2) PCD Milling Inserts
Common models like APMT,SEET, mainly used for high speed milling surface (milling speed above 3000m/min). It can obtain high surface roughness, and can obtain long tool life, which help the customers lower the processing costs.
(3) Chip-breaker PCD Inserts
It is make slot through laser on the cutting edge of a standard machine-clamp blade, mainly used for solve the chips problems, avoid the scratch on the component.
(4) PCD Grooving Inserts
It can include round tips and flat tips. The insert width will include 2mm, 3mm and 4mm, it also can be customized size as the customers’ requirements. It can be used for machining cylinder grooves, inner grooves, end surface grooves.

Part 3 Machining Materials of PCD Inserts

PCD Inserts can be used for machining ferrous metal together with their alloy and some non-metal composites.
(1) Non-ferrous metal materials and their alloys: such as aluminum alloy, magnesium aluminum alloy, silicon aluminum alloy, copper alloy, copper, brass, tungsten carbide hard alloy, ceramics, etc.
(2) Non-metallic materials: such as composite materials, carbon fiber, glass fiber, graphite, wood, stone, urethane rubber, glass, reinforced plastic, etc.

Part 4 The application Field of PCD Inserts

PCD Inserts are mainly used for precision machining of difficult-to-process non-ferrous and non-metallic materials. Currently, the common application industries include:
(1) Automobile industry (including some other power machinery): such as aluminum alloy piston, aluminum alloy wheel hub, aluminum alloy cylinder head and other parts, the main material is aluminum alloy, silicon aluminum alloy, high silicon aluminum alloy, mainly using PCD Inserts , PCD Grooving Inserts and PCD wheel hub turning tools. For this application, CDW010, CDW025 and CDW302 materials can meet the requirements of wear resistance, processing efficiency, processing quality, smoothness and precision.
(2) Wind power industry: At present, the main materials used in this field are fiber reinforced composite materials (CFRP, GFRP, AFRP, BFRP, etc.). The main materials of wind power blades are glass fiber and carbon fiber, mainly using PCD Inserts and PCD milling Inserts. Commonly used materials include CDW010, CDW025 and CDW302.
(3) High Precision machining Field: PCD inserts are generally used for high precision cutting. Due to the high hardness of PCD material, high thermal conductivity, rapid heat transfer, low friction coefficient, and low affinity with non-ferrous metals, high precision can be obtained. (within a few wires), high processing finish, can be used for glass mirror processing.

Part 5 Halnn PCD Grade

Grade	Granularity（μm）	Characteristics	Application
CDW850	Submicron	Ultra-fine grain structure, strong edge sharpness and edge durability	High precision machining, mirror surface machining, suite for aluminum alloy that required high on the chipping performance, mainly used for machining Ti alloy and other composites
CDW002	2μm	High cobalt content, Good electrical machine performance, excellent toughness, Good roughness machining, more convinent for complec tool processing	Mainly used for engrave milling cutter and thread cutting tool, and also cutting tools for wear-resistant parts, used in woodworking saws, particleboard and the tools for machining silicon aluminum alloy
CDW005	5μm	Excellent electric spark and machinability, good toughness, wear resistance and edge quality	It suits for good surface quality processing, mainly used for machining PMMA, Silicion alloy and metal cell phone shell outlin and used in the wood cutting tools, saws industry
CDW010	10μm	Universal PCD Grade, good toughness and high abrasive resisitance	Suit for single tool for rough machining, especially for wood molding, medium and low silicon aluminum alloy parts (such as piston).
CDW025	25μm	High wear resistance and edge quality	Suit for high Silicion Aluminum alloy, MMC, Tungsten carbide and ceramic, graphite,wear resistant parts, mainly used in wood Wood finishing insert and saws
CDW302	2~30μm	Mixed 2μm and 25μm,good wear resistance and edge quality and edges strength	It mainly used for machining MMC, high Silicion Aluminum calloy, high strength cast iron and other application.

Part 6 PCD Inserts Cutting Parameters for Reference

(1) Cutting speed/Vc
PCD inserts can be used at very high spindle speeds. When machining different work piece materials, the cutting speed of PCD insert is also different. For example, PCD inserts can cut aluminum alloys at speeds up to 1000m/min, and the life is Dozens of times of tungsten carbide inserts.
(2) Feed Rate/Fr
The feed amount of the PCD Insert is different according to the work piece material, and can be recommended according to the cutting parameters of the tool manufacturer. For example, the feed amount of the aluminum alloy processed by the CDW010 material PCD blade is in the range of 0.03-0.5;
(3) Cutting Depth Ap
PCD inserts are often used for semi-finishing and finishing. The cutting depth ap of aluminum alloys processed by CDW010 is generally 0.1-3mm, and the depth of high silicon aluminum alloy (greater than 13% Si) is not more than 2.5mm.

The actual cutting parameters of the PCD insert should be determined according to the specific processing conditions. The following table is recommended for the cutting parameters of Halnn PCD inserts when processing different materials:

Component Materials		Recommend PCD Grade				Cutting Condition
Component Materials		Recommend PCD Grade				Vc（m/min）	Fr（mm/r）	ap（mm）
Aluminum alloy	4-8%Si	CDW010	CDW302	CDW005	CDW850	100-5000	0.03-0.5	0.1-3.0
	9-13%Si	CDW010	CDW302		CDW850	100-3000	0.03-0.5	0.1-3.0
	＞13%Si	CDW010	CDW302	CDW025	CDW850	100-2500	0.03-0.4	0.1-2.5
Copper alloy	Copper, zinc, brass	CDW010	CDW302	CDW025	CDW850	100-1000	0.03-0.3	0.1-3.0
Titanium alloy		CDW850	CDW005			100-200	0.05-0.2	0.1-2.0
Tungsten Carbide	Co < 16%	CDW302	CDW025	CDW010		15-40	0.1-0.25	0.1-1.0
Tungsten Carbide	Co > 16%	CDW302	CDW025	CDW010		10-30	0.03-0.1	0.05-0.3
Reinforced plastic						100-1000	0.05-0.3	0.1-2.0
Wood		CDW010	CDW302	CDW005	CDW002	100-4000	0.1-0.4	0.1-3.0
Graphite		CDW302	CDW025	CDW010		100-600	0.1-0.5	0.05-2.0
Metal matrix composites	A1/10-20%Si	CDW302	CDW025	CDW010		300-600	0.1-0.4	0.2-1.5
Composite	Carbon Finber	CDW302	CDW025	CDW010		200-2000	0.05-0.3	0.1-3.0

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