Selecting the correct cutting-tool material depends on the material being machined, the tool geometry, machine conditions, production volume, required surface finish and expected tool life.
This guide compares PCD, tungsten-carbide-tipped tools, solid carbide and HSS, explaining where each material is commonly used and the main factors to consider before selecting a tool.
Prima Tooling manufactures and services standard and bespoke cutting tools in each of these materials. For application-specific requirements, view our bespoke cutting-tool manufacturing service.
PCD (Polycrystalline Diamond)
1. a cutting material with very high hardness and wear resistance. It is commonly used for machining aluminium, copper, brass, graphite, CFRP, GFRP and other abrasive non-ferrous or composite materials.
Its main benefits include:
- Excellent resistance to abrasive wear
- Long and predictable tool life in suitable applications
- Good surface finish and dimensional consistency
- Suitability for high cutting speeds
- Reduced frequency of tool changes during production
2. Considerations and applications
PCD tools generally cost more to manufacture than carbide or HSS tooling, but the additional cost can be justified by longer service life, improved process consistency and reduced machine downtime.
The tool geometry, PCD grade and flute configuration should be selected according to the component material, machining operation, machine conditions and required finish.
For examples of available geometries, view our PCD end mills for composite materials.
Where technically suitable, worn tooling may also be considered for PCD sharpening, retipping and repair.
TCT (Tungsten Carbide Tipped)
1. Properties and benefits
TCT tools use tungsten-carbide cutting tips brazed onto a steel tool body. This construction combines the wear resistance of carbide with the strength and stability of a steel body.
TCT tooling is commonly used for machining timber, MDF, plywood, plastics and some non-ferrous materials.
Its main benefits include:
- Good wear resistance at a lower initial cost than PCD
- Greater toughness than PCD in interrupted or less stable cutting conditions
- Steel bodies that can support larger and more complex cutter designs
- Suitability for a wide range of woodworking and general machining applications
- The potential for repeated sharpening and replacement of damaged tips
2. Considerations and applications
TCT is often a practical choice where production volumes or material abrasiveness do not justify PCD tooling. Cutting performance and tool life will depend on the carbide grade, cutting geometry, material being machined and machine conditions.
Although tungsten carbide is wear resistant, cutting edges can still chip if the tool is overloaded, damaged or used in an unsuitable application.
View examples of our TCT and carbide-tipped router cutters.
Worn or damaged tools may also be suitable for TCT sharpening, retipping and repair.
Solid Carbide
1. Properties and benefits
Solid-carbide tools are manufactured from cemented tungsten carbide throughout the cutting portion and tool body, rather than using separate cutting tips brazed onto steel.
This construction provides high hardness, wear resistance and rigidity. Solid carbide is used for router cutters, spiral tools, end mills, drills and other precision cutting tools.
Its main benefits include:
- High rigidity for accurate machining
- Good resistance to abrasive wear
- Ability to maintain a sharp cutting edge
- Suitability for high cutting speeds in stable machining conditions
- Availability in complex flute and cutting geometries
- Use across woodworking, plastics, composites, non-ferrous materials and engineering applications
2. Considerations and applications
Solid carbide is harder but generally less tolerant of shock, vibration and excessive runout than HSS. Incorrect feeds, poor clamping or unstable machining conditions can cause the cutting edge to chip or the tool to break.
The most suitable carbide grade, coating, flute count and cutting geometry will depend on the material, machining operation, machine rigidity and required surface finish.
For woodworking and CNC routing applications, view our solid-carbide router tooling.
Worn tools may also be suitable for solid-carbide sharpening and regrinding.
HSS (High-Speed Steel)
1. Properties and benefits
HSS is a tough alloy tool steel that retains useful hardness at elevated cutting temperatures. It is less wear resistant than carbide or PCD, but its toughness makes it suitable for applications where the tool may experience shock, vibration or interrupted cutting.
HSS is commonly used for drills, profile cutters, knives and specialist cutting tools, particularly where production quantities are modest or a complex bespoke profile is required.
Its main benefits include:
- Good toughness and resistance to edge chipping
- Suitable for intricate and special-purpose cutting profiles
- Easier to sharpen and regrind than many harder cutting materials
- Practical for short production runs and lower cutting speeds
- Cost-effective for suitable general-purpose applications
2. Considerations and applications
HSS generally requires lower cutting speeds than solid carbide or PCD and will wear more quickly when machining highly abrasive materials. Its suitability depends on the material being cut, tool geometry, machine conditions and required production volume.
For unusual profiles or application-specific designs, Prima Tooling can manufacture bespoke HSS cutting tools.
Existing tooling may also be suitable for HSS sharpening, repair and reconditioning.
Conclusion
Choosing the right cutting-tool material
No single cutting-tool material is suitable for every machining application. The best choice will depend on the component material, cutting operation, machine conditions, production volume, required surface finish, expected tool life and overall tooling cost.
PCD may provide the longest service life in abrasive non-ferrous and composite materials, while TCT offers a versatile and economical option for many woodworking applications. Solid carbide provides high rigidity and wear resistance in stable machining conditions, while HSS remains valuable where toughness, complex profiles or lower production quantities are important.
Prima Tooling can review your application and recommend a suitable tool material, geometry and servicing strategy. To discuss a current application, contact Prima Tooling for cutting-tool advice.