From aluminium and magnesium to fibre-reinforced plastics, PCD cutting tools are designed to handle them all. This capability is due, in part, to the inherent hardness of this synthetic PCD material, which results in PCD milling tools from Ceratizit being able to hold their own against extremely abrasive materials, both in terms of tool life and attainable quality.
Thanks to the development of additive manufacturing processes, cutter geometries that were difficult or even impossible to produce with conventional technologies are now a reality. For example, the number of cutting edges on a milling cutter can be maximised with 3D printing, which in turn significantly increases chip removal rate. Such a factor, along with high cutting speeds and strategically placed coolant channels, delivers major benefits in terms of reduced cycle times.
Performance is also enhanced by the high helix angle to ensure quiet running at elevated rotational speeds. The screw-in type PCD cutters from Ceratizit are available in diameters from 10 to 32 mm, with projection (flute) lengths of 2.5xD, and tool length being varied through the use of appropriate tool holders. PCD milling cutters can also be supplied in hybrid form with a solid-carbide base body.
For those companies machining graphite, the latest Ceratizit PCD tools offer high performance; with up to four cutting edges they are able to run at very high cutting speeds. In addition, the end mills bring distinct processing advantages when it comes to the circular milling of holes or grooves. Here, far fewer radius corrections are required before tool life ends, in comparison to solid-carbide tools. This capability means the milling cutters last longer, as the extremely abrasive nature of graphite has little effect on them. The result is that time-consuming tool changes and adjustments become a thing of the past, minimising idle time and delivering consistent machining quality.
