Knight Carbide–THE ADVANTAGES OF PCD AND CBN CUTTING TOOLS IN HIGH-PRECISION MACHINING

Superabrasives: Are Synthetic Diamonds A Machinist’s Best Friend?

Polycrystalline Diamond (PCD) and Cubic Boron Nitride (CBN) cutting tool inserts offer several significant benefits in high-precision machining. They enhance tool performance, extend tool life, and improve overall machining efficiency. While the advantages PCD and CBN cutting tools are significant, they can cost two or three times as much as their carbide equivalents. Knowing when and how to splurge for a superabrasive tool is key to reaping the benefits of this impressive technology.

The Advantages of PCD and CBN in High-Precision Machining

In the world of high-precision machining, success and failure are often mere microns apart. The quality, efficiency and cost-effectiveness of your process are all affected by your choice of cutting tool. Since its introduction to the US market in 1982, PCD has become indispensable to industries requiring ultra-precise tooling of non-ferrous metals like aluminum, brass, and copper, as well as composites, fiberglass, wood, ceramics, plastics, and other non-metallic materials. For hardened steels and superalloys, CBN provides a similarly effective solution. 

Hardness and Wear Resistance

First on the list of the many compelling attributes of PCD and CBN  is their hardness. A synthetic diamond material, PCD is known to be the second hardest human-made substance on the planet. CBN follows closely behind. This quality lets these superabrasives maintain sharp cutting edges far longer than carbide cutting tools when machining their respective materials. That means fewer tool changes, less downtime, along with better dimensional control and superior finish quality over greatly extended runs.

Superior Surface Finish

Aerospace, automotive, and other high-precision machining industries require superior surface finishing. PCD and CBN, with their super-sharp cutting edges and low friction coefficients are well-suited to the task, leaving mirror-like finishes  

Increased Productivity and Cost-Effectiveness

The higher cost of superabrasive tools, which can run two or three times that of carbide tools, can be offset over time. Greatly extended tool life significantly cuts tooling costs by reducing the frequency of replacement. With their high thermal resistance, PCD and CBN tools can run at higher cutting speeds and feed rates, improving productivity. Longer tool life and greater efficiency combine to lower costs per part, making these tools economically beneficial for high-volume, high-precision machining operations.

PCD and CBN Cutting Tools: Are They Worth the Money?

From faster feed rates to reduced frequency of tool replacement, to higher efficiency and improved finish quality, the advantages of PCD and CBN tools are amplified as production volume increases. For cost analysis purposes, while these premium cutting tools can cost two or three times as much as the same tool in tungsten carbide, the superabrasive versions can be expected to last at least 25 times longer in the same application.