In precision cutting, the cutting tools used matter. They affect performance, efficiency, and product quality.
Two leading materials for form cutting tools are PCD (polycrystalline diamond) and CBN (cubic boron nitride).
This guide explores PCD and CBN features, benefits, and uses to help you choose the best material for your needs.
What are PCD and CBN?
PCD and CBN are synthetic materials that engineers design to withstand extreme cutting conditions. So, each design works under different circumstances to suit specialized industrial uses.
PCD: Made from sintered diamond crystals and a metal binder, PCD is renowned for its unmatched hardness and wear resistance. Thus, it’s ideal for non-ferrous materials like aluminium, copper, and composites.
CBN: Composed of boron and nitrogen, CBN is slightly less hard than PCD but offers exceptional thermal stability and wear resistance at high temperatures. CBN tools are best for machining ferrous materials like hardened steel and cast iron.
Key Differences Between PCD and CBN Form Cutting Tools
1. Hardness and Wear Resistance
- PCD Tools: Best for low-to-moderate hardness materials. For instance, their diamond composition ensures superior wear resistance, making them ideal for high-volume cutting. However, they’re unsuitable for ferrous materials due to diamond’s reactivity with iron.
- CBN Tools: Although not as hard as PCD, it excels in machining harder, heat-treated materials. They’re particularly effective for ferrous metals like steel and cast iron.
2. Thermal Stability
- PCD Tools: Perform well at high speeds but are less stable than CBN at extreme temperatures.
- CBN Tools: Offer excellent thermal stability, making them ideal for high-speed machining and heat-treated steel operations.
3. Cost
- PCD Tools: More expensive than CBN due to the complexity of PCD manufacturing, but their long tool life can save costs in high-volume applications.
- CBN Tools: More affordable than PCD but still a big investment. Their cost-effectiveness depends on the specific machined materials and application.
4. Machining Applications
- PCD Tools: Ideal for non-ferrous materials like aluminum, copper, and composites. Commonly used in PCD drill bits, PCD tool components, and PCD tool solutions for automotive (engine parts) and aerospace (titanium alloys) industries.
- CBN Tools: Best for machining ferrous materials such as hardened steel, cast iron, and superalloys. Widely used as CBN cutters and CBN tools in automotive (gears, bearings), and aerospace (high-performance steel parts).
Choosing the Right Tool for Your Industry
Use PCD or CBN form cutting tools based on your materials and operations.
| Automotive Industry |
PCD Tools: Best for machining lightweight alloys and composites such as engine blocks and cylinder heads. CBN Tools: Essential for hardened steel components such as gears, bearings, and crankshafts. |
| Aerospace Industry |
PCD Tools: Ideal for non-ferrous materials such as aluminum and titanium alloys. CBN Tools: Crucial for finishing high-performance steel parts under extreme stress. |
| Tooling and Manufacturing |
PCD Tools: Superior for composites and non-ferrous materials. CBN Tools: Better for heat-treated ferrous materials. |
Which Is Right for Your Industry?
Understanding the unique benefits of CBN and PCD helps you make the right choice for your operations.
In short, both PCD and CBN tools have big advantages and it all depends on your specific needs.
In many cases, a combination of PCD and CBN tools can optimize performance and efficiency.
Asime offers cutting-edge PCD and CBN tools solutions tailored to your industry. By leveraging their benefits, you can enhance precision, efficiency, and product quality in your manufacturing processes.
Suggested read: How Precision Cutting Tools Boost Automotive Performance?
