What is PCD End Mill? What kind of problems does it help you with?
PCD End Mill is a high-end cutting tool designed for nonferrous metals and composites. As the core representative of ultra-hard tools, it is specially designed for aluminum alloy, copper alloy, carbon fiber composite materials, high silicon aluminum and other non-ferrous materials. It is widely used in high-end manufacturing fields such as 3C electronics, new energy vehicles, aerospace and medical equipment. It has become a key tool to overcome difficult machining materials and improve production efficiency.
If you are processing the following materials:
1. aluminium alloy
2. New energy automobile motor shell
3. copper alloy
4. Carbon fiber/composites
5. Graphite, ceramic based materials
Then you must have had these problems
1. Tool wear fast
2. Surface damage, burrs
3. Poor size consistency, high batch risk
4. Frequent tool change, low efficiency, high labor costs
PCD End Mill exists to solve these problems. At Wangdefu, our PCD cutters are widely used in high-precision scenarios such as Automotive Parts Prototype, New Energy Vehicle Housing, Humanoid Robot Components, etc., helping customers reduce risk before mass production.
Core Technology Advantages
1. Extreme material, performance overruns traditional tools
PCD End Mill uses high-quality polycrystalline diamond tips, hardness up to 8000-10000HV, 8-12 times that of cemented carbide; thermal conductivity up to 700W/(m·K), heat dissipation speed is 3-9 times that of cemented carbide, effectively avoiding high temperature tool sticking in the cutting area; friction coefficient is only 0.1-0.3, chip discharge is smooth, and the machined surface roughness can be as low as Ra≤0.1μm.
2. Precision technology, customized adaptation requirements
Relying on five-axis linkage laser processing and ultra-short pulse laser cutting technology, the blunt radius of the edge after fine grinding is ≤0.005mm, and it supports customization of flat bottom, round nose, ball head and special-shaped edge, and adapts to various processing scenarios such as complex cavity, micro-groove and curved surface. Three types of structures can be selected, such as welded type, indexable type and integral type, to meet the requirements of different machine tools and processing efficiency.
3. Particle size adaptation, targeted to overcome processing difficulties
Provide 2-10μm fine grain, 10-25μm medium grain, 25-50μm coarse grain diamond particle size selection, fine grain for pure aluminum, copper alloy finishing, medium grain for high silicon aluminum general processing, coarse grain for carbon fiber, stone and other wear-resistant materials rough processing, accurately match different material processing needs.
4. Efficient cost reduction, double leap in life and efficiency
PCD End Mill life is 50-200 times that of traditional cemented carbide milling cutter, 3C electronic field single processing time can be shortened from 30 minutes to 20 seconds, efficiency increased by 90 times; new energy automobile motor shell processing, cutting efficiency increased by 40%, comprehensive processing costs reduced by more than 60%.
Product Parameters
|
Parameter Type |
Specification Range |
|
Tool Type |
Flat-end PCD Milling Cutter, Round-nose PCD Milling Cutter, Ball-nose PCD Milling Cutter, Custom-shaped PCD Milling Cutter |
|
Structure Type |
Welded Type, Indexable Type, Solid Type |
|
Diamond Grain Size |
Fine grain: 2-10μm; Medium grain: 10-25μm; Coarse grain: 25-50μm |
|
Cutting Diameter |
Regular: 0.5-20mm; Special specifications available for customization |
|
Shank Diameter |
4-10mm (Tolerance H6, compatible with various precision clamping systems) |
|
Effective Flute Length |
3-15mm; Long overhang models customizable |
|
Machining Precision |
Dimensional tolerance: ±0.003-±0.01mm; Surface roughness: Ra≤0.1μm |
|
Maximum Cutting Speed |
Up to 800-3500m/min for aluminum alloy machining |
|
Cooling Method |
External cooling / Internal cooling (High-pressure internal cooling optional, pressure ≥5MPa) |
|
Applicable Materials |
Aluminum alloy, Copper alloy, High-silicon aluminum (Si≥12%), Carbon fiber composite material, Ceramic matrix composite material, Graphite, etc. |
Where can PCD End Mill be used?
1.3C electronics field: fine milling of mobile phone middle frame and aluminum case, micro-groove processing of ceramic substrate, size accuracy ±0.003mm, surface finish Ra=0.05μm, meeting the stringent requirements of precision electronic components.
2. New energy vehicle field: motor housing, battery module end milling, piston processing, flatness ≤0.01mm, no need for follow-up polishing, to assist efficient mass production of lightweight manufacturing of automobiles.
3. Aerospace field: carbon fiber composite wing skeleton, composite components deep cavity milling, burr-free, delamination-free processing, in the long overhang conditions still maintain stable rigidity.
4. Medical device field: orthopedic implants, high-precision surgical instruments complex contour processing, no metal contamination, sharp edges, meet the ultimate surface requirements of biocompatible materials.
Recommended cutting parameters
|
Workpiece Material |
Tool Type |
Cutting Speed (Vc) |
Feed per Tooth (fz) |
Axial Depth of Cut (Ap) |
|
Aluminum Alloy (Si<10%) |
Solid PCD Milling Cutter |
800-3500m/min |
0.10-0.25mm |
0.5-3.0mm |
|
High-Silicon Aluminum (Si≥12%) |
Medium-Grain PCD Milling Cutter |
500-1500m/min |
0.08-0.15mm |
0.3-2.0mm |
|
Carbon Fiber Composite Material |
Coarse-Grain PCD Milling Cutter |
200-600m/min |
0.05-0.15mm |
0.2-1.0mm |
|
Copper Alloy |
Ball-Nose PCD Milling Cutter |
500-1500m/min |
0.05-0.20mm |
0.05-1.5mm |
It is strictly prohibited to process ferrous metals to avoid tool graphitization failure; cutting temperature should be controlled below 750℃, it is recommended to match high-pressure internal cooling system; specific parameters need to be fine-tuned according to machine rigidity and workpiece structure, customized tools will provide exclusive parameter solutions.
Why are more and more customers choosing Wangdefu?
1. A true PCD End Mill manufacturer with its own factory.
2. Deep participation in automotive and new energy projects
3. Tool + tooling + process plan available
4. Project Manager 1 to 1 Follow-up
5. High communication efficiency and fast response
After-sales support and service
1. Installation and use instructions
2. Parameter optimization suggestions
3. Wear and Failure Analysis
4. 48 hour technical response
What is PCD End Mill? What kind of problems does it help you with?
PCD End Mill is a high-end cutting tool designed for nonferrous metals and composites. As the core representative of ultra-hard tools, it is specially designed for aluminum alloy, copper alloy, carbon fiber composite materials, high silicon aluminum and other non-ferrous materials. It is widely used in high-end manufacturing fields such as 3C electronics, new energy vehicles, aerospace and medical equipment. It has become a key tool to overcome difficult machining materials and improve production efficiency.
If you are processing the following materials:
1. aluminium alloy
2. New energy automobile motor shell
3. copper alloy
4. Carbon fiber/composites
5. Graphite, ceramic based materials
Then you must have had these problems
1. Tool wear fast
2. Surface damage, burrs
3. Poor size consistency, high batch risk
4. Frequent tool change, low efficiency, high labor costs
PCD End Mill exists to solve these problems. At Wangdefu, our PCD cutters are widely used in high-precision scenarios such as Automotive Parts Prototype, New Energy Vehicle Housing, Humanoid Robot Components, etc., helping customers reduce risk before mass production.
Core Technology Advantages
1. Extreme material, performance overruns traditional tools
PCD End Mill uses high-quality polycrystalline diamond tips, hardness up to 8000-10000HV, 8-12 times that of cemented carbide; thermal conductivity up to 700W/(m·K), heat dissipation speed is 3-9 times that of cemented carbide, effectively avoiding high temperature tool sticking in the cutting area; friction coefficient is only 0.1-0.3, chip discharge is smooth, and the machined surface roughness can be as low as Ra≤0.1μm.
2. Precision technology, customized adaptation requirements
Relying on five-axis linkage laser processing and ultra-short pulse laser cutting technology, the blunt radius of the edge after fine grinding is ≤0.005mm, and it supports customization of flat bottom, round nose, ball head and special-shaped edge, and adapts to various processing scenarios such as complex cavity, micro-groove and curved surface. Three types of structures can be selected, such as welded type, indexable type and integral type, to meet the requirements of different machine tools and processing efficiency.
3. Particle size adaptation, targeted to overcome processing difficulties
Provide 2-10μm fine grain, 10-25μm medium grain, 25-50μm coarse grain diamond particle size selection, fine grain for pure aluminum, copper alloy finishing, medium grain for high silicon aluminum general processing, coarse grain for carbon fiber, stone and other wear-resistant materials rough processing, accurately match different material processing needs.
4. Efficient cost reduction, double leap in life and efficiency
PCD End Mill life is 50-200 times that of traditional cemented carbide milling cutter, 3C electronic field single processing time can be shortened from 30 minutes to 20 seconds, efficiency increased by 90 times; new energy automobile motor shell processing, cutting efficiency increased by 40%, comprehensive processing costs reduced by more than 60%.
Product Parameters
|
Parameter Type |
Specification Range |
|
Tool Type |
Flat-end PCD Milling Cutter, Round-nose PCD Milling Cutter, Ball-nose PCD Milling Cutter, Custom-shaped PCD Milling Cutter |
|
Structure Type |
Welded Type, Indexable Type, Solid Type |
|
Diamond Grain Size |
Fine grain: 2-10μm; Medium grain: 10-25μm; Coarse grain: 25-50μm |
|
Cutting Diameter |
Regular: 0.5-20mm; Special specifications available for customization |
|
Shank Diameter |
4-10mm (Tolerance H6, compatible with various precision clamping systems) |
|
Effective Flute Length |
3-15mm; Long overhang models customizable |
|
Machining Precision |
Dimensional tolerance: ±0.003-±0.01mm; Surface roughness: Ra≤0.1μm |
|
Maximum Cutting Speed |
Up to 800-3500m/min for aluminum alloy machining |
|
Cooling Method |
External cooling / Internal cooling (High-pressure internal cooling optional, pressure ≥5MPa) |
|
Applicable Materials |
Aluminum alloy, Copper alloy, High-silicon aluminum (Si≥12%), Carbon fiber composite material, Ceramic matrix composite material, Graphite, etc. |
Where can PCD End Mill be used?
1.3C electronics field: fine milling of mobile phone middle frame and aluminum case, micro-groove processing of ceramic substrate, size accuracy ±0.003mm, surface finish Ra=0.05μm, meeting the stringent requirements of precision electronic components.
2. New energy vehicle field: motor housing, battery module end milling, piston processing, flatness ≤0.01mm, no need for follow-up polishing, to assist efficient mass production of lightweight manufacturing of automobiles.
3. Aerospace field: carbon fiber composite wing skeleton, composite components deep cavity milling, burr-free, delamination-free processing, in the long overhang conditions still maintain stable rigidity.
4. Medical device field: orthopedic implants, high-precision surgical instruments complex contour processing, no metal contamination, sharp edges, meet the ultimate surface requirements of biocompatible materials.
Recommended cutting parameters
|
Workpiece Material |
Tool Type |
Cutting Speed (Vc) |
Feed per Tooth (fz) |
Axial Depth of Cut (Ap) |
|
Aluminum Alloy (Si<10%) |
Solid PCD Milling Cutter |
800-3500m/min |
0.10-0.25mm |
0.5-3.0mm |
|
High-Silicon Aluminum (Si≥12%) |
Medium-Grain PCD Milling Cutter |
500-1500m/min |
0.08-0.15mm |
0.3-2.0mm |
|
Carbon Fiber Composite Material |
Coarse-Grain PCD Milling Cutter |
200-600m/min |
0.05-0.15mm |
0.2-1.0mm |
|
Copper Alloy |
Ball-Nose PCD Milling Cutter |
500-1500m/min |
0.05-0.20mm |
0.05-1.5mm |
It is strictly prohibited to process ferrous metals to avoid tool graphitization failure; cutting temperature should be controlled below 750℃, it is recommended to match high-pressure internal cooling system; specific parameters need to be fine-tuned according to machine rigidity and workpiece structure, customized tools will provide exclusive parameter solutions.
Why are more and more customers choosing Wangdefu?
1. A true PCD End Mill manufacturer with its own factory.
2. Deep participation in automotive and new energy projects
3. Tool + tooling + process plan available
4. Project Manager 1 to 1 Follow-up
5. High communication efficiency and fast response
After-sales support and service
1. Installation and use instructions
2. Parameter optimization suggestions
3. Wear and Failure Analysis
4. 48 hour technical response