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Machining carbide with PCD solid head milling cutters

Posted on 04 Dec 2021 and read 2642 times
Machining carbide with PCD solid head milling cuttersProduct overview of the new PCD solid head milling cutters in relation to a match

Rugby-based MAPAL Ltd has introduced a new range of PCD solid head milling cutters that offer short process times and long tool lives when machining carbide and other hard-brittle materials to smaller diameters.

Deep-drawing dies in the die and mould sector are often made of durable carbide. Machining them by die-sinking or grinding is laborious, while machining with coated solid carbide tools results in high wear and low tool life. PCD tools can offer a cost-effective alternative.

The punches and moulds usually require tools with diameters less than 6mm and so to execute these tool dimensions in PCD, full-head PCD must be used — smaller milling cutters have no room for brazed-on cutting edges and their substructure.

With new geometry, number of cutting edges and arrangement, MAPAL now makes it possible to machine hard-brittle workpiece materials with diameters from 2 to 6mm.

To produce the perfect PCD tool according to customer requirements, blanks are kept in stock in a variety of sizes. PCD is more expensive than solid carbide, but thanks to the longer tool life and shorter process times, break even is quickly reached. In tests, the new milling cutters managed significantly higher feeds per tooth compared to solid carbide and therefore a much higher machining volume.

In addition to carbide, hard-brittle materials also include zirconia, a ceramic material used in dental technology. The new PCD solid head milling cutters from MAPAL are also an alternative to solid carbide in this area.