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TechTalk

Synthetic Tools That Will Allow You to Cut Through Even the Hardest Metals

For nearly 100 years, Tungsten Carbide tools have been used because of their strength and durability. However, PCD and PCBN tools are becoming a lot more popular because they can cut the hardest metals on the market. With such great qualities, PCD and PCBN tools are outshining their competitors a little more each day. These synthetic tools are commonly used in manufacturing because they offer better results, such as minor chipping or deformation due to cutting.

PCD (Polycrystalline Diamond), also known as Sunpax, is made by mixing a synthetic diamond powder with a bonding agent. This mixture is subjected to high pressure and heat (sintering) to create high-precision tools such as Sunpax. These tools are designed to be resistant to abrasions and undergo less wear and tear. When used in precision metal finishing, Polycrystalline Diamond offers better dimensional accuracy. With this product, you are guaranteed consistent product quality with a service life that will outlast other tools.

What Are PCD Tools Used For?

• Cutting nonferrous metals
• Cutting nonmetals
• Used to create materials that are used in wear-resistant tools

PCBN (Polycrystalline Cubic Boron Nitride), also known as Sunnite, is made by mixing a CBN (Cubic Boron Nitride) powder with a bonding agent. The mixture is put under extreme heat and pressure to create tools suitable for cutting tough metals. These tools are chemically stable, produce lower friction, and offer excellent thermal conduction.

Examples of tough metals are hardened and heat-resistant steels such as cast iron or carbon steel. PCBNs have a high level of hardness and offer a better wear resistance than carbides and ceramics. They are also less resistant to oxidation, acids, and alkalis, which provide stable performance after multiple uses.

• High-speed dry cutting
• Automotive Industry

CBN (Cubic Boron Nitride) is a synthetic compound that is just below the strength of a diamond. CBN may be slightly weaker than a diamond, but it offers better thermal stability when used on ferrous metals. This molecular composition makes it a great additive to increase the strength and longevity of tools such as PCBNs.

Are PCD and PCBN Tools the Future in Cutting Tools?

PCD and PCBN tools are showing to be very useful in milling, drilling, and cutting projects. They are durable and offer better resistance to wear when compared to tools made from Tungsten carbide. These tools are made from synthetic mixes that can be altered or added to other mixtures to create more robust and even more durable tools than they are on their own.

A Tungsten carbide tool can smooth or shape cast iron, whereas PCBN tools can drill through this thick metal. Each tool possesses different qualities. For instance, PCD tools are sharp, and PCBN tools are vital and handle thermal conductivity very well. There is the possibility that these synthetic tools are the cutting tools of the future. However, it will take time to see what the industrial and milling industries choose as their tool of preference.

What’s Going to Happen with Tungsten Carbide?

Tungsten Carbide tools have been used for about 90 years. These tools have been considered top quality, but the price provokes people to purchase more affordable tools. If PCD and PCBN tools can compete in cost, then there is the possibility that Tungsten carbide tools will get cheaper or fade out of the market. Synthetic tools are a lot more affordable to manufacture. Considering the product is a lot more durable helps to see that Tungsten carbide may become obsolete at some point or another.

If we consider data available for 2000-2005, we can see that these synthetic tools went from a value of $230 million to $460 million. The growth rate shows that these tools are proliferating and will be around for years to come. According to the market today, sales of PCD and PCBN tools will grow from 2020-2025. The estimated growth has not been released to the public. However, the tools have been assessed on a market scale, and it is evident that they are growing in popularity among many industries.

• Automobile Industry
• Industrial Industry
• Machining Operations
• Mining Operations

PCD (Polycrystalline Diamond) and PCBN (Polycrystalline Cubic Boron Nitride) tools have been used in the automotive industry since the mid-1980s. In recent years these tools have begun to gain an excellent reputation because they are designed to have long-term cutting life and can cut at a very rapid rate. When we look at the quality of the tools accompanied by the market data, it becomes evident that these durable tools will not fade out of the market any time soon.

 

If you have any questions about carbide cutting tools, PCD, and PCBN be sure to reach out to us @ sctools.co/Home or call us at (877)737-0987. We help you machine better!