PCD cutting tools are widely used where abrasive materials, long production runs and consistent machining performance place high demands on the cutting edge.
Polycrystalline diamond has extremely high resistance to abrasive wear. In suitable applications, this allows PCD tooling to maintain its cutting geometry considerably longer than conventional carbide tooling.
Benefits of PCD Cutting Tools
The main advantages of PCD cutting tools can include:
- longer tool life
- fewer tool changes
- reduced machine downtime
- consistent cutting geometry
- improved dimensional consistency
- more stable surface finish
- lower tooling cost per finished component
For an explanation of how PCD is manufactured and the materials it can machine, see our What Is Polycrystalline Diamond (PCD)? article.
Longer Tool Life in Abrasive Materials
One of the principal advantages of PCD is its resistance to abrasive wear.
Materials such as MDF, HDF, particle board, laminated panels and many composite materials can wear conventional carbide cutting edges relatively quickly. PCD can provide substantially longer service life when the material, cutting geometry and machining conditions are suitable.
Longer tool life can be particularly valuable in continuous production, where every tool change interrupts the machining process.
More Consistent Production
As a cutting edge wears, dimensions and surface finish can gradually change.
Because PCD can retain its cutting geometry for extended periods, it can help manufacturers maintain more consistent machining results across longer production runs.
This can be important for applications such as panel processing, profiling and trimming, edgebanding, routing and grooving, composite machining and repetitive CNC production.
Consistent tooling performance can also reduce operator intervention and make production planning more predictable.
Reduced Downtime and Tool Changes
The purchase price of a PCD cutter is normally higher than an equivalent carbide tool, but purchase price alone does not show the full production cost.
Tool changes can involve machine stoppage, operator time, resetting, checking dimensions and restarting production.
For high-volume machining, extending the interval between tool changes can therefore provide a significant productivity advantage.
Lower Cost per Component
For suitable applications, the useful comparison is often cost per finished component rather than the initial cost of the cutter.
Factors can include purchase price, expected tool life, number of service cycles, machine downtime, operator involvement, scrap and rework, and consistency of finished components.
A higher-cost PCD tool that operates significantly longer can therefore be more economical over its complete working life.
PCD or Carbide?
PCD is not automatically the best choice for every machining application.
Carbide can remain the more economical solution for shorter production runs, frequently changing profiles and applications where the additional tool life of PCD would not justify the higher initial cost.
Where materials are abrasive and production volumes are high, however, PCD can provide a substantial advantage.
Prima Tooling manufactures tooling in PCD, TCT and solid carbide, allowing the cutting material and geometry to be selected around the actual machining requirement.
Servicing PCD Tooling
Many PCD tools can be sharpened, re-eroded, repaired or retipped during their working life.
Correct servicing can extend the useful life of suitable tooling while retaining the cutting geometry required for consistent production.
See our Sharpening, Retipping & Tool Repair service for more information.
PCD Tooling from Prima Tooling
Prima Tooling manufactures standard and bespoke PCD tooling for woodworking, panel processing, composites and other industrial machining applications.
For woodworking and panel applications, explore our Wood & Composite Wood Tooling.
For composite machining, see our Composite Tooling and PCD End Mills.
If you would like us to review an existing tool or machining application, contact Prima Tooling.