In the correct application, the service life of PCD tools is almost 20 times that of the same carbide tools. The new generation of integral PCD spiral end mills and drills will further expand this advantage. In the 3C and aerospace manufacturing industries, there is a huge demand for tools that can provide higher productivity and quality.
The integral PCD tools has many advantages. Most importantly, the tool geometry has complete flexibility. Spiral cutting tools (including drills and end mills) have superior cutting performance compared with the same tools with brazed PCD inserts.
Traditional PCD rotary cutting tools usually braze the PCD insert to the body of the carbide tool. Although PCD can extend the life of the cutting edge, according to the design, the geometry of the cutting edge is a shear (straight) edge with a straight rake angle. This geometry itself limits the performance of the tool.
Integral PCD tools can create various unique geometric shapes more flexibly to meet different cutting applications in the same way as traditional cemented carbide tools. This applies not only to the cutting profile, but also to the grinding of slotting and tooth gap geometry, which is essential for chip formation and emptying. Another important consideration is that the minimum diameter of brazed PCD tools is usually 6mm, but overall PCD tools can easily be made into tools smaller than this diameter. Micro tools (drills and end mills) are widely used in the 3C market. More Super Hard can produce drills with a minimum of 0.3 mm and milling cutters of less than 3 mm.
Finally, unlike coated carbide tools, these new drills and end mills can be easily reground multiple times, effectively extending the tool life.
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