Maximising tool life is vital in today’s manufacturing. It increases productivity, reduces costs, and leads to better machining quality.
Choosing the right cutting inserts cuts downtime and enhances machining efficiency. The best options are polycrystalline diamond (PCD) and cubic boron nitride (CBN) inserts. They are both known for their strength and accuracy.
Specialized inserts tailored for specific machining challenges further enhance tool performance while maximizing tool life.
What are PCD Inserts Used For?
Superior for Non-Ferrous and Abrasive Materials – PCD Inserts
PCD inserts, or diamond insert cutting tools, are created using synthetic diamond particles. These particles are combined by applying high heat and pressure. They excel in machining non-ferrous metals, composites, and abrasive materials like:
- Aluminium alloys (especially high-silicon content)
- Copper, brass, and bronze
- Carbon fiber-reinforced polymers (CFRP) and fiberglass
- Ceramics and Graphite
PCD inserts are very hard. This helps them resist wear, so you do not have to change tools as often. They also offer better surface finishes. Thus, it reduces the need for more finishing work.
CBN Insert Full Form and Its Benefits
The Best Choice for Hard Metals – CBN Inserts
CBN inserts are made from cubic boron nitride. It is the second hardest material, after diamond. They excel in machining ferrous materials, such as:
- Hardened steel (above 45 HRC)
- Cast iron (gray and ductile)
- Superalloys (nickel-based and cobalt-based)
CBN grooving inserts are excellent for high-speed, dry machining. They handle heat very well. Also, they stay sharp, so they remove metal faster. Thus, this keeps precision and tool life intact.
The Role of Special Inserts in Tool Optimization
Some cutting inserts, like standard PCD and CBN ISO inserts, perform very well. Special inserts, on the other hand, meet specific machining needs. Custom inserts are designed for specific operations, such as:
- Precision finishing for aerospace and automotive parts.
- Interrupted cutting which requires high impact resistance.
- Complex geometries that need specialized edge profiles.
Special inserts cut down on tool failure. They work by refining design, coatings, and wear patterns, which increases efficiency.
Key Benefits of Using PCD, CBN, and Special Inserts
1. Extended Tool Life
PCD and CBN inserts last much longer than regular carbide inserts. This means fewer tool changes, less downtime, and lower overall tooling costs.
2. Improved Machining Efficiency
High-speed machining removes material faster, reducing cycle times. So, it is ideal for industries requiring high-volume production.
3. Superior Surface Finish
PCD inserts deliver exceptional finishes on non-ferrous and abrasive materials. On the other hand, CBN inserts create a mirror-like finish on hardened steels. This means there is no need for additional finishing.
4. Heat and Wear Resistance
CBN inserts excel in dry machining, reducing coolant use and supporting environmental sustainability. PCD inserts, on the other hand, help stop material build-up. Hence, it keeps tools from chipping and makes them last longer.
5. Cost Savings Over Time
PCD and CBN inserts have a higher initial cost than carbide inserts. But their long life and high performance help cut machining costs in the end.
Best Practices for Maximizing Tool Life
To make the most of PCD, CBN, and special inserts, follow these best practices:
1. Optimize Cutting Parameters
- Use the recommended cutting speeds, feed rates, and depth of cut for each material.
- Avoid excessive force to prevent premature tool failure.
2. Proper Tool Handling & Storage
- Keep inserts in a clean, dry place to avoid contamination and damage.
- Handle with care to prevent edge chipping or cracking.
3. Use the Right Insert Geometry
- Select the proper rake angles and edge preparations based on the machining needs.
- Use special inserts with chamfered or honed edges for tough applications.
4. Regular Machine Maintenance
- Ensure spindles and tool holders are in good shape to prevent vibrations.
- Calibrate machines regularly to maintain precision.
5. Monitor Tool Wear and Performance
- Use predictive maintenance strategies to track insert wear.
- Replace inserts before they cause workpiece damage.
Investing in PCD, CBN, and Special Inserts for Maximum Efficiency
PCD, CBN, and special inserts improve tool life, boost productivity and improve machining quality.
Their durability, heat-resistance, and precision make them ideal for industries like aerospace, automotive, and high-performance machining.
Manufacturers can improve efficiency while reducing tooling costs by using best practices for maximizing tool life and picking the right cutting insert.
Upgrade Your Tooling Today!
Look at Asime’s range of PCD, CBN, and custom inserts to elevate your machining performance. Our metal cutting inserts are high quality. They help you improve efficiency in CNC machining!
Browse through Asime’s range of PCD, CBN, and custom inserts to enhance your machining performance. Our high-quality metal cutting inserts help you achieve higher operational efficiency in CNC machining!
Suggested read: PCD vs. CBN Form Cutting Tools: Which One is Right for Your Industry?
