The benefits of PCD cutting tools include exceptional wear resistance, long tool life and consistent cutting performance. PCD, or polycrystalline diamond, is a synthetic diamond material made from many microscopic diamond particles bonded together under high pressure and temperature.
For cutting-tool applications, the diamond particles form an extremely hard and wear-resistant cutting material. The PCD layer is commonly supported by a tungsten-carbide substrate, which provides strength and makes it practical to incorporate the material into cutting tools.
PCD has become an important cutting material for industries that machine abrasive materials and require long tool life, consistent dimensions and reliable surface finish.
How Is Polycrystalline Diamond Made?
Manufacturers produce PCD by sintering synthetic diamond particles at extremely high pressure and temperature in the presence of a metallic binder.
This process bonds the individual diamond particles together to form a polycrystalline structure rather than a single diamond crystal. Cutting-tool grades can use different diamond grain sizes and compositions depending on the required balance between cutting-edge quality, wear resistance and toughness.
Benefits of PCD Cutting Tools
Diamond is extremely hard and highly resistant to abrasive wear. As a result, PCD cutting edges can maintain their geometry for long periods when machining suitable materials.
The main benefits can include:
- long tool life
- high wear resistance
- consistent cutting geometry
- improved dimensional consistency
- reduced frequency of tool changes
- consistent surface finish during longer production runs
These benefits of PCD cutting tools can make the material particularly valuable in high-volume production, where tool changes and declining edge quality affect productivity and cost per component. PCD manufacturers likewise highlight wear resistance, dimensional control and extended tool life as key advantages.
What Materials Can PCD Machine?
PCD performs particularly well when machining abrasive non-ferrous and non-metallic materials.
Typical applications include:
- MDF, HDF and particle board
- laminated and melamine-faced panels
- wood-plastic composites
- carbon-fibre reinforced plastic (CFRP)
- other abrasive composite materials
- aluminium and aluminium alloys
- copper and other suitable non-ferrous materials
PCD is widely used in woodworking because materials such as MDF, laminates and particle board can cause rapid wear to conventional carbide cutting edges. It is also established for composite machining, including CFRP, and for non-ferrous metal applications such as aluminium.
For examples of these applications, see our Wood & Composite Wood Tooling and Composite Tooling ranges.
PCD Tooling for CNC Machining
Prima Tooling manufactures PCD cutting tools for a wide variety of CNC applications.
These include profile and router cutters for woodworking and panel processing as well as precision PCD End Mills for machining composites and other abrasive materials.
Because the cutting geometry and PCD grade can influence tool performance, the correct tool should match the material, machine and required finish rather than simply replacing an existing carbide cutter with PCD.
Can PCD Tools Be Sharpened or Retipped?
One of the additional advantages of many PCD tools is that they can be serviced during their working life.
Depending on the tool design and condition, Prima Tooling can sharpen, re-erode, repair or retip suitable PCD tooling. This can extend the useful life of the tool and reduce the need for complete replacement.
See our Sharpening, Retipping & Tool Repair service for more information.
Need Advice About PCD Tooling?
If you are considering PCD tooling for a particular material or machining application, contact Prima Tooling. We can advise whether PCD is suitable and recommend or manufacture tooling for the application.