PCD inserts (polycrystalline diamond inserts) are a popular choice for manufacturing operations in a wide range of industries. With their exceptional hardness, toughness, and wear resistance, PCD inserts offer many advantages over other types of cutting tools. In this article, we will explore what PCD inserts are, how they are made, and what makes them such a popular choice for manufacturing operations.
What are PCD Inserts?
PCD inserts are cutting tools that are made from a material called polycrystalline diamond. Unlike natural diamonds, which are formed over millions of years deep within the earth's mantle, PCD is made by sintering together diamond particles under high pressure and high temperature. The resulting material is incredibly hard and durable, making it an ideal choice for cutting tools.  
How are PCD Inserts Made?
The process of making PCD inserts involves several key steps:
Diamond Powder: The first step in making PCD inserts is to obtain the diamond powder that will be used to make the PCD material. This powder is typically made from synthetic diamonds that have been crushed into small particles.
Sintering: The diamond powder is then sintered together under high pressure and high temperature to create the PCD material. During this process, the diamond particles bond together to form a solid material that is nearly as hard as natural diamond.
Cutting Tool Manufacturing: The PCD material is then cut and shaped into the desired form for use as a cutting tool. This can include inserts for use in milling and turning operations, as well as other types of cutting tools.
 
What Makes PCD Inserts Advantageous?
PCD inserts offer several key advantages over other types of cutting tools:
Hardness: PCD inserts are incredibly hard, with a hardness of up to 10,000 Vickers. This means they can cut through even the hardest materials, including metals and composites.
Wear Resistance: PCD inserts are also highly wear-resistant, which means they can maintain their cutting edge for much longer than other types of cutting tools. This means less downtime for tool changes and greater productivity for manufacturing operations.
Toughness: PCD inserts are also tough and able to withstand high temperatures and stresses. This makes them ideal for use in high-speed machining operations and other demanding manufacturing environments.
Surface Finish: PCD inserts can produce very fine surface finishes on the materials being cut. This is due to their exceptional sharpness and wear resistance, which allows them to cut through materials cleanly and efficiently.
Cost-Effective: While PCD inserts can be more expensive than other types of cutting tools, they are also more cost-effective in the long run. This is because they last longer and require less frequent tool changes, which can save manufacturers money in the long run.
PCD inserts are a popular choice for manufacturing operations due to their exceptional hardness, toughness, wear resistance, and surface finish capabilities. While they may be more expensive than other types of cutting tools, their long lifespan and cost-effectiveness make them an ideal choice for many manufacturing operations. If you are in the market for cutting tools, it is worth considering PCD inserts as an option for your manufacturing needs.