TM d.o.o. has been producing diamond PCD and PCBN tipped tools since 2001. In 2003 after thorough and well prepared development of the manufacturing process, we achieved outstanding results.
If You are not familiar with polycrystalline diamond (PCD), we will introduce it to You very shortly with a few key facts:
Polycrystalline Diamond (PCD) is a synthetic diamond product that is produced by sintering together selected diamond particles with a metal matrix, using sophisticated technology. The diamond and matrix, when sintered together under high temperatures and pressures, creates a PCD tool blank that is high in uniform hardness and is abrasive resistant in all directions. This PCD diamond layer is then bonded to a tungsten carbide substrate, which provides strength and a brazable base to permit bonding to other metals.
Polycrystalline tipped tools are exceptionally resistant to wear compared to tungsten carbide or ceramic tools. In certain applications, PCD tool life can exceed carbide cutting tool life 50 to 100 times.
In certain applications, polycrystalline tipped tools have several advantages over natural diamond:
PCD is more shock resistant than natural diamond because of its random orientation structure of the diamond particles, and is backed by a carbide substrate.
PCD is more constant in wear. The reason for this is the random orientation of diamond particles. Natural diamond is a single crystal in nature and has soft and hard grains. Depending on the shape of the natural diamonds and the tool being manufactured, it is sometimes not practical to have hardest grain on the cutting edge.
PCD is available in a large variety of shapes and sizes. Discs as large as 50mm in diameter are now available. Natural diamond is limited to that formed in nature. Diamond, even with only an 8mm long cutting edge, is extremely difficult to find and is very costly.
PCD blank costs are considerably lower than the costs of natural diamond stones, and the availability of various shapes of PCD blanks reduce manufacturing cost significantly. The longer the required cutting edge is, the larger are the savings of PCD over natural diamond, due to the rarity of larger stones.
Polycrystalline diamond tooling can be used in a wide range of machining operations such as milling, grooving, turning, facing and boring. They are recommended for machining non ferrous metals and abrasive non metallics.
PCD tipped cutting tools can easily be damaged, so the cutting edges of tool should be protected with rubber or plastic cap when the tools are not in use. When not in use on the machine, store PCD cutting tools in separate boxes.
When you measure tools, the use of the optical measuring devices is highly recommended. If you have no other choice but to use micrometer or height micrometer, please use copper or plastic washers to avoid damaging of the cutting edges. Do not put the PCD tool in contact with workpiece when the machine is still, or stop the machine durning feed.
High cutting speed reduces the pressure on cutting edge, but be aware that slow speed increases the pressure which may cause higher wear, or even the chipping of the cutting edges.
The machine should be in excellent condition, due to the fact that vibrations reduce PCD tipped cutting tool lifetime.
Examples from our production: