Cutting carbide with pcd tools

Carbide, characterized by its significant hardness and brittleness, is commonly employed in tool materials, molds, and various wear-resistant parts. Traditionally, carbide was shaped and refined primarily through grinding due to its hardness. However, with the advancement of superhard tools, particularly Polycrystalline Diamond (PCD) tools, cutting carbide has become an efficient alternative. Here’s a detailed exploration of the process and benefits of using PCD tools for cutting carbide.

Characteristics of Carbide Material

1. High Hardness and Brittleness: Carbide has a hardness rating of HRA87-95(HRC67~82), making it considerably harder than most hardened steels. This extreme hardness contributes to its brittleness and lack of plasticity, posing challenges in machining due to potential edge chipping under mechanical stresses.
2. Powdered Chip Formation: The brittleness of carbide leads to chip formation in powder form, facilitating a smoother finished surface.
3. High Thermal Conductivity and Lower Cutting Temperatures: Carbide’s thermal conductivity ranges from 17W/(m·k) to 88W/(m·k), vastly exceeding that of hardened steel and thus resulting in lower temperatures during the cutting process.
4. Concentrated Cutting Forces: The cutting forces in carbide machining are concentrated near the cutting edge, which accelerates tool wear, particularly in the form of flank wear.

Machining Carbide with PCD Tools

Using PCD tools to machine carbide involves several considerations to mitigate the material’s inherent brittleness:

Our factory business: We design, develop and produce powder metallurgy moulds, carbide parts, powder injection moulds, stamping toolings and precision mould parts. Whatsapp:+8618638951317. Email: [email protected], 

• Strategic Feed Rate Adjustments: At the entry and exit points of a cut, reducing the feed rate or introducing a chamfer can help minimize edge chipping.
• Maintaining a Sharp Cutting Edge: A sharp edge is crucial for reducing stress concentrations that can lead to tool degradation.
• Use of Cutting Fluids: Implementing kerosene as a cutting fluid can facilitate the cutting process, helping to manage the heat and reduce tool wear.

Advantages of PCD Tools in Carbide Machining

1. Enhanced Mold Performance: Cutting with PCD tools generates residual compressive stresses on the surface of tungsten cobalt carbide molds, improving their strength and performance. This contrasts with the high temperatures and potential damage caused by traditional grinding methods.
2. Increased Efficiency: PCD tools can significantly enhance cutting efficiency, offering a more rapid production rate compared to other machining methods.
3. Improved Tool Longevity: PCD tools exhibit superior durability, extending the operational life and reducing the frequency of tool replacements.

Conclusion

For industries reliant on precision and durability, such as automotive or aerospace, the use of PCD tools for machining carbide offers a substantial improvement in both productivity and quality. The technological advances in PCD tooling not only provide a viable alternative to traditional grinding but also advance the capabilities in machining high-hardness materials like carbide. By adopting PCD tools, manufacturers can achieve more efficient, cost-effective, and high-quality production processes, essential for maintaining competitive advantage in high-stakes markets.

For further inquiries or to explore carbide machining solutions tailored to your needs, feel free to contact our technical experts. We’re here to assist in optimizing your production with the best tools and techniques available.