Or, you might think you are getting a bargain when you buy the tool, only to find you are going to be expected to pay 50% of the new tool cost to get it sharpened. If you neglect to get answers to these questions, you might be in for a surprise to find you were sold a “disposable” tool that cannot be sharpened at all, or can only be sharpened once. How long will it take to turnaround a tool when sharpening? How many times will I be able to sharpen this tool under normal wear conditions? To understand the complete picture and compare “apples to apples” when shopping, it is important to ask the following questions: don’t order a tool with 1.1/4″ cut length when you only cut 3/4″ material because that needlessly increases the tool cost. In particular, you want to be certain that there is no more PCD on the tool than actually needed (i.e. When shopping for a PCD tool, it is important to discuss your proposed use and expectations in detail with the tool manufacturer as this allows for selection of the proper PCD grade (grain size), and optimum tool design. Meanwhile, there are a number of synthetic diamond tool blank manufacturers, and the quality, durability and wear resistance is not always equal. The original developers of synthetic diamond were GE (Specialty Materials Division) and DeBeers (Element 6) who pioneered this process and mastered the know-how of synthesizing diamond for industrial cutting applications. Depending on what material is being machined, it is not unheard of for a diamond tool to outrun carbide by a ratio of 300 : 1! Nevertheless, when deciding whether to switch, be conservative in your cost analysis and base your decision on the diamond bit lasting 25x longer than carbide. Examples are: particleboard, MDF, OSB, high pressure laminate, phenolic, fibre glass etc. PCD has an exceptionally high wear resistance factor, in particular with abrasive composite materials that are often difficult to machine with carbide. Polycrystalline diamond is manufactured in a high-pressure, high-temperature laboratory process that fuses diamond particles onto a carbide substrate, which, in turn, allows the diamond to be brazed onto a tool body. So, if you are machining different materials and want one tool to do it all, the diamond tool will not be able to excel as well as it will if you are machining, for instance, 3/4″ MDF all day long. Diamond tooling is not advisable as an all-round tool that will be required to meet demands of a wide range of cutting applications on a day to day basis. First and foremost, think of it as the marathon runner, as it will yield the best results in continuous and steady cutting of homogeneous materials. Understanding the basics of diamond tooling is important when contemplating its use in your own production line. Under the right conditions and with proper maintenance and handling, significant cost savings can be achieved by running polycrystalline diamond (PCD) tooling. Carbide : Weighing the Costs and Benefits
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