PCD Insert for Composite Materials
Polycrystalline diamond (PCD) inserts are the definitive solution for machining modern composite materials, delivering unparalleled precision, surface finish, and tool life. These engineered materials, including CFRP, GFRP, and various aerospace-grade laminates, demand cutting tools that eliminate delamination, fiber pull-out, and matrix damage. Our specialized PCD inserts are designed with sharp, honed edges and specific geometries to achieve clean shearing of fibers and a polished cut. For optimal results in complex profiles and finishing operations, our PCD Diamond-Shaped Insert offers superior access and versatility. When machining highly abrasive composites or non-ferrous metals mixed with reinforcing particles, our Wear-Resistant PCD Insert provides exceptional longevity, drastically reducing downtime. For aluminum, copper, and magnesium alloys, the PCD Insert for Non-Ferrous Metals ensures high-speed, high-feed machining with a mirror-like finish. Ultimately, every challenging application benefits from a tailored approach, which is why we engineer Application-Specific PCD Insert solutions to meet exact customer requirements for geometry, edge preparation, and substrate.
Every **PCD Insert for Composite Materials** in our portfolio is the result of rigorous engineering and advanced manufacturing processes. We select only the finest synthetic diamond grains, sintered under high pressure and temperature to create a uniform, ultra-hard cutting edge. This PCD layer is securely bonded to a robust carbide substrate, providing the necessary strength and impact resistance. The geometry of each insert is meticulously designed, featuring large positive rakes and polished flutes to minimize cutting forces and heat generation—critical factors for preventing workpiece damage. A comprehensive chamfer or hone is applied to the cutting edge to enhance durability without compromising sharpness. We offer a wide range of standard sizes and shapes, including round, square, and trigon, to suit various machining operations from roughing to super-finishing. For custom requirements, our technical team collaborates closely with clients to develop the perfect tool geometry and edge preparation.
Key Parameters of Our PCD Inserts for Composites
- Diamond Layer Thickness: Available in 0.5mm, 1.0mm, 1.5mm, and 2.0mm options.
- Substrate Material: Premium tungsten carbide (Grades K10/K20) for maximum stability.
- Cutting Edge Preparation: T-land, honed, or sharp edge, tailored to material type.
- Rake Angle: Highly positive geometries (15° to 25°) for free-cutting action.
- Coating: Optional non-stick PVD coatings (e.g., TiN) to reduce built-up edge.
- Applicable Operations: Trimming, edge-profiling, drilling, and pocket milling of composites.
| Insert Style |
Standard Size (IC) |
Corner Radius |
Primary Application |
Recommended Feed Rate (mm/tooth) |
| Round (R) |
6mm - 20mm |
N/A |
Contour profiling, finishing |
0.10 - 0.30 |
| Square (S) |
10mm - 25mm |
0.2mm, 0.4mm, 0.8mm |
Shoulder milling, face milling |
0.08 - 0.25 |
| Trigonal (T) |
8mm - 16mm |
0.2mm, 0.4mm |
General purpose milling |
0.12 - 0.35 |
| Diamond (D) |
6.5mm - 15mm |
0.1mm, 0.2mm |
Complex contours, fine details |
0.05 - 0.20 |
Machining Parameters Guide for Composite Materials
| Composite Type |
Cutting Speed (Vc) m/min |
Depth of Cut (ap) mm |
Coolant Recommendation |
| Carbon Fiber (CFRP) |
200 - 350 |
0.5 - 3.0 |
Compressed Air or Minimum Quantity Lubrication (MQL) |
| Glass Fiber (GFRP) |
180 - 300 |
0.5 - 2.5 |
Compressed Air or Dry |
| Aramid Fiber |
150 - 250 |
0.3 - 1.5 |
Compressed Air only |
| Metal Matrix Composites (MMC) |
100 - 200 |
0.2 - 1.0 |
Flood Coolant or MQL |
