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PCD for Machining Nonferrous Materials and CBN Inserts for Machining Hard Materials, Dry Cutting, and High Speed Machining
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With the introduction of new PCD and CBN compositions, ISCAR is providing the industry with a wider application range, mainly in machining of nonferrous materials, hard steel and cast iron. Brazed tips made of PCD and CBN are used on standard ISO inserts (i.e. triangular, rhombic, square and round) and on ISCAR's unique GRIP inserts. The polycrystalline diamond (PCD) tips provide excellent surface finish when machining aluminum, and other nonferrous and nonmetal materials. Much longer tool life is achieved, even at high cutting speeds, due to the high wear-resistance and excellent thermal conductivity.
The ID6 grade with larger diamond grains is suitable for machining aluminum alloys with more than 12% Si, cemented tungsten carbide, and for interrupted milling of aluminum alloys. The ID5 grade with medium diamond grain size of 8 to 9 microns is recommended for general machining applications, for Cu alloys and for Al alloys with less than 12% Si. The fine-grain ID4 with 4 to 5 micron grain size is recommended for machining composite plastic materials, wood, and pure aluminum.
Cubic boron nitride (CBN) inserts are available in five different grades. This very hard material is used for machining difficult-to-cut materials, sintered metals, super alloys, hardened steel, and cast iron. Machining of heat treated, hardened steel with CBN provides high surface quality and eliminates, in many cases, grinding - a process that is normally required when machining steel with a hardness over 45 HRc. The use of CBN provides significant improvement in productivity and economy utilizing high speed machining and hard machining.
Grades IB50 and IB65 are used for semi-finishing and finishing of hardened steel with 45 to 55 HRc. Grade IB80 provides excellent performance for heavy interrupted cutting on hardened steel and for machining cast iron with high Cr content. IB90 is recommended for high-speed cutting of cast iron and for cutting cemented tungsten carbide, sintered metals and heavy alloys and interrupted cutting of hardened steel.
For rough and medium cutting of hardened steel and high speed cutting of cast iron, IB90A, a solid CBN insert, can be used. The CBN tool edges are provided with a small negative land of about 0.1mm (.039 inch) width and 20° negative rake angle to resist chipping.
The PCD inserts are commonly used in the Aerospace, Automotive, Hydraulic, and Household Appliance industries. The CBN inserts are primarily used in the Automotive industry, for bearing production and for machining of dies and molds.
The wide variety of PCD and CBN grades offered by ISCAR enables optimization of application and machining conditions in order to improve performance and economy of metal cutting.
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