PCD & PCBN Tool Precision Grinding Solutions

PCD (Polycrystalline Diamond) and PCBN (Polycrystalline Cubic Boron Nitride) are core tool substrates widely used in aerospace, new energy vehicles, 3C precision electronics, high-end woodworking, powder metallurgy hard turning and milling fields. Restricted by their ultra-high hardness, high-temperature graphitization tendency and strict micron-level edge processing requirements, the mass production yield and efficiency of tool manufacturers have long been troubled. With more than ten years of in-depth research and development in super-hard diamond grinding wheels, Moresuperhard has launched a full range of custom grinding wheels and standardized grinding process systems targeting PCD/PCBN grinding industry pain points. We support complete-process solutions including cooling, dressing and quality inspection, helping more than 800 tool manufacturers worldwide achieve low-damage, high-consistency and cost-effective tool grinding production.

Core Technical Difficulties in PCD/PCBN Super-Hard Tool Grinding

Inherent Processing Challenges of Materials

Ultra-high hardness aggravates grinding wheel wear
PCD hardness ranges from HV 5000 to 8000, and PCBN hardness ranges from HV 3500 to 5000. Ordinary low-grade diamond abrasives are prone to fragmentation, leading to rapid passivation of grinding wheels, frequent shutdown dressing and increased overall processing costs.

High-temperature graphitization damage of PCD
The cobalt-based binder inside PCD has a catalytic effect. When the temperature exceeds 700°C, graphitization phase transformation occurs on the PCD surface, and large-area graphite damage appears above 850°C, resulting in edge blackening, micro-cracks and sharp decline in tool service life. It is impractical to control the grinding temperature below 200°C in actual mass production. The universal industry standard is to limit the peak grinding contact temperature ≤ 450°C, and inhibit thermal damage from the source through the coordinated control of grinding wheel structure, cooling system and grinding parameters.

Strict micron-level high-precision edge standards
The edge radius of general industrial tools is required to be R≤5~10μm; high-end precision tools for aerospace and semiconductor industries stably require R≤2~3μm with zero chipping, zero micro-notches and zero subsurface graphite damage, which cannot be stably achieved by conventional grinding schemes in mass production.

Significant grinding performance differences of different binders
PCD adopts cobalt/silicon bonding phase, while PCBN is divided into metal and ceramic binders. The two materials have obvious differences in hardness and thermal conductivity. A single type of grinding wheel cannot adapt to the processing of both materials, so abrasives, binders and grinding parameters need to be customized according to tool materials.

EDM processing is only applicable to rough shaping
Electrical Discharge Machining (EDM) can remove surplus materials quickly, but it will cause surface graphitization and subsurface micro-damage to tools, so it is only limited to rough processing. Precision finishing of high-end tools must adopt mechanical grinding with diamond grinding wheels to produce damage-free mirror edges.

Contradiction between grinding wheel service life and processing efficiency
The strong abrasiveness of PCD and PCBN materials greatly shortens the service life of diamond grinding wheels. Frequent dressing occupies machine tool working hours, and most tool manufacturers face the production dilemma of "improved precision with reduced production capacity".

Full Custom Design Scheme of Moresuperhard Diamond Grinding Wheels

All products strictly comply with FEPA international abrasive standards, adapt to global mainstream 5-axis tool grinding machines such as ANCA, EWAG, Walter and Coborn, and support one-on-one customized non-standard special-shaped grinding wheels.

High-grade Synthetic Diamond Abrasive Selection (Moresuperhard Self-developed Nickel-plated High-strength Diamond)

All Moresuperhard abrasives adopt nickel plating technology to improve the bonding force between abrasive grains and binder. The service life of our grinding wheels is more than 35% longer than that of ordinary domestic products, effectively reducing dressing frequency and downtime.

Three Major Binder Grinding Wheel Product Lines

Standard Parameters of Grinding Wheel Concentration and Hardness

1. Concentration Range: 125%~200% for rough grinding; 75%~125% for finish grinding. Moresuperhard can customize ultra-high concentration wheels of 150% and 175% to disperse grinding load.
2. Hardness Grade: NR and R-grade ultra-hard wheels for PCD grinding to resist strong abrasion; N~P-grade medium and high hardness wheels for PCBN processing.

Custom Standards for Grinding Wheel Shape and Structure

Moresuperhard Exclusive Structural Optimization Design

1. Dual Matrix Options: Tungsten steel high-rigidity matrix to avoid grinding deformation; lightweight aluminum alloy matrix to reduce machine spindle load.
2. Uniform Cooling Hole Design: Large-diameter wheels are equipped with heat dissipation holes to strengthen heat exchange in the grinding zone and greatly reduce graphitization risk.
3. Full Factory Dynamic Balance Inspection: Every wheel undergoes high-speed dynamic balance testing before delivery to eliminate edge vibration lines and chipping from the source.

Moresuperhard Standardized Grinding Process Parameter Optimization Scheme

Verified by mass production in thousands of tool factories, the process parameters cover three mainstream workpieces: welded PCD milling inserts, integral PCBN turning inserts and PCD woodworking saw blades, which can be directly put into production.

PCD Milling Insert Edge Grinding (Aerospace / 3C Precision Tools, Target R≤5μm)

Rough Grinding Process (Reserved Margin: 0.03~0.05mm, Rapid Material Removal)

Finish Grinding Process (Form Micron-level Complete Edge, Zero Chipping & Zero Graphitization)

PCBN Hardened Steel Turning Insert Grinding (Negative Chamfer Finishing)

PCBN has better thermal stability than PCD, allowing appropriately increased grinding speed to balance processing efficiency and chamfer dimensional consistency.

Mass Grinding of PCD Woodworking Saw Blade Tips

Matching metal-bonded diamond grinding wheels to effectively extend dressing cycle and improve saw blade daily output.

1. Wheel linear speed: 20~25m/s, single cutting depth: 0.005~0.01mm with layered multi-pass feed.
2. Conventional dressing interval: Dress every 20~50 teeth, adjustable according to saw blade substrate.
3. Supporting consumables: Moresuperhard provides special silicon carbide dressing rods for one-stop procurement to reduce customer supporting costs.

Standardized Grinding Wheel Dressing System for Extended Wheel Service Life

Grinding wheels passivate much faster in PCD/PCBN grinding conditions than in cemented carbide grinding. Moresuperhard has sorted out three standardized dressing schemes suitable for different production scales.

Quick Judgment Standards for Grinding Wheel Passivation

1. Continuous increase of machine spindle load and obvious increase of grinding noise;
2. Fine edge chipping and significant deterioration of tool surface roughness;
3. Continuous scratches and local blackening (slight graphitization) on edges under microscope.

2~3 times of non-feed spark-out processes must be carried out after dressing to remove dressing burrs on the wheel surface and avoid workpiece scratches.

Three Mature Mass Production Process Cases of Moresuperhard

Solution A: Precision Grinding of Welded PCD Milling Inserts (Aerospace / New Energy 3C Tools, Edge R≤5μm)

Rough Grinding: Moresuperhard vitrified bonded diamond wheel D30~D46, 200% concentration, R-grade hardness; linear speed 20m/s, single cutting depth 0.003mm, oil-based cooling, reserved margin 0.03mm.
Finish Grinding: Self-developed resin bonded wheel D7~D15, 100%~125% concentration; linear speed 18m/s, nano-scale micro cutting depth, 4 times non-feed spark-out.
Customer Effect: Zero edge chipping, graphitization scrap rate reduced from 12% to 0.8%, grinding wheel service life increased by 40%.

Solution B: Negative Chamfer Grinding of Integral PCBN Turning Inserts (Hardened Steel Cutting Tools)

Adopt Moresuperhard medium-hard vitrified diamond wheel D15~D20, 150% concentration; wheel linear speed 25m/s, single cutting depth 0.001~0.002mm; constant-temperature oil-based cooling. The batch chamfer width error is ≤0.002mm, which significantly improves product consistency.

Solution C: High-efficiency Grinding of PCD Woodworking Saw Blades (Automatic Mass Production Line)

Custom Moresuperhard metal bonded diamond wheel D20~D30, 150% concentration; wheel linear speed 22m/s, layered feed with single cutting depth 0.005mm; matched with special silicon carbide dressing rods. The dressing interval is doubled, and the daily output of single machine is increased by 30%.

Core Advantages of Moresuperhard Products & Services

1. Product Hard Strength

1. Self-owned abrasive and binder formula R&D and production line, supporting FEPA standard and non-standard special-shaped wheel customization, covering full mainstream models including 1A1/6A2/11V9/12V9.
2. Full grain size coverage from D3 to D91, fine-grain products meet mirror polishing requirements, compatible with all super-hard tool substrates such as CVD/MCD/PCD/PCBN.
3. Three factory inspections: abrasive strength test, high-speed dynamic balance verification and profile accuracy inspection, zero defective products delivered.
4. Fully compatible with imported tool grinders such as ANCA, EWAG, Walter, Coborn, Campbell and Junker, directly replacing imported wheels without machine modification, reducing comprehensive procurement cost by 50%.

2. Industry Customer Coverage

We have served more than 800 tool manufacturing enterprises worldwide, covering five core tracks: new energy vehicle tools, aerospace precision tools, 3C electronic diamond tools, woodworking saw blades and bearing PCBN turning tools. With a large number of mature import substitution cases, the comprehensive processing efficiency is increased by 20%~40% under the same processing accuracy.

Industry Summary & Cooperation Inquiry

The core pain points of PCD/PCBN super-hard tool grinding focus on high-temperature graphitization inhibition, stable micron-level edge forming, and balance between wheel life and mass production efficiency. Simply adjusting machine parameters cannot completely solve processing defects. An integrated solution of custom diamond grinding wheels + standardized grinding process + precise cooling system + standardized wheel dressing is essential.

As a high-tech enterprise specializing in super-hard abrasive tools, Moresuperhard has more than ten years of front-line practical experience in PCD/PCBN tool grinding. We provide full-chain services including wheel selection, process debugging, supporting consumables and long-term technical follow-up, helping enterprises reduce tool scrap rate, extend grinding wheel service life and improve batch processing stability.