Our daily focus is on tailor-made special solutions for the use of diamond and CBN tools.
The rising demands within the industry highlight the growing need for PCD and CBN tools, especially in specialized designs. The increasing application of highly abrasive materials in modern manufacturing underscores that carbide tools often reach their performance limits. Consequently, there is a louder call for more economical tool solutions.
For decades, diamond and CBN tools have revolutionized the production processes of various enterprises across multiple sectors.
Your advantage lies in our expertise, passion for diamond tools, and our capacity to implement innovative applications for your specific needs.
In addition to delivering specialized solutions, we consult and assist our clients on optimizing processes—from engineering to the tool's actual application. Our in-house and field service teams collaborate closely with clients to explore every inquiry and together devise potential solutions. We oversee tool construction, assess tool perfection, and support its use at the customer’s site. We continuously enhance our staff’s knowledge to ensure that our tools are seamlessly integrated into our clients’ production workflows.
The result is high-precision tools that improve our clients’ production processes by making them more efficient, cost-effective, and sustainable—providing longer tool life, higher feed rates leading to fast and precise processing, tailored services, and optimized machining efficiency.
Under the right conditions and with adequate maintenance, substantial cost savings can be achieved using polycrystalline diamond (PCD) tooling. It's essential to grasp the fundamentals of diamond tooling when considering its application in your production line. Firstly, view it akin to a marathon runner, as it excels in steady and sustained cutting of uniform materials. However, diamond tooling is not the optimal choice as a versatile tool for varied cutting applications.
PCD is produced through a high-pressure, high-temperature manufacturing process that fuses diamond particles to a carbide substrate. This enables the diamond to be brazed onto a tool body, providing exceptional wear resistance, especially with abrasive composite materials that are challenging to machine with carbide. It's not uncommon for a diamond tool's lifespan to exceed that of carbide tools by a factor of 300:1, depending on the material processed.
However, when contemplating a switch to diamond tooling, conduct a conservative cost analysis based on the assumption that a diamond tool will last 25 times longer than its carbide counterpart. You will not be disappointed!
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If you are looking for more details, kindly visit customized diamond saw factory.
The original developers of synthetic diamond include GE (Specialty Materials Division) and DeBeers (Element 6), who were pioneers in this field. However, as various manufacturers now produce synthetic diamond tool blanks, quality, durability, and wear resistance may vary.
When selecting a PCD tool, discussing your intended use and expectations with the manufacturer is vital. This ensures the proper PCD grade (grain size) and optimal tool design are chosen. Specifically, avoid ordering excess PCD on the tool than necessary, as this can unnecessarily inflate costs.
To fully understand and make accurate comparisons when shopping, ask these critical questions:
How many times can I sharpen this tool under regular wear conditions?
What will sharpening this tool cost?
What is the turnaround time for sharpening?
Failing to obtain the answers could lead to surprises, such as purchasing a tool that is effectively disposable or incurs high sharpening costs. These factors significantly influence cost per linear foot machined and are crucial for cost justification when considering PCD tooling. Below is a cost comparison example between a diamond saw blade and a carbide-tipped blade:
$./$. = PCD costs 19.6% of carbide when comparing $/Linear Foot (80.4% cost reduction)
Another notable advantage of PCD tooling is the superior finish quality, which often requires less sanding, unlike carbide tools that deteriorate in quality from the first cut. A diamond tool maintains an excellent finish until it's dull, at which point it needs sharpening. Pushing a diamond tool past its dull point can lead to significant sharpening costs due to potential damage.
While at first glance, PCD tooling appears cost-prohibitive compared to carbide, analyzing the cost per linear foot machined reveals PCD as the superior choice in the right applications. The investment in PCD tools pays off quickly, particularly for machining abrasive materials, composites, and high-volume, uniform cuts.
For PCD router bits, maintaining proper chip load is crucial, as heat buildup during cutting can damage the diamond and lead to tool failure. Proper tool clamping systems with tight tolerances and secure material hold-down are essential to minimize any vibrations during the cut. For specific inquiries about PCD tooling, please reach out to us or call us at 1-800-544-xxxx.
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