The company has introduced a full range of PCD and CBN end mills that are pre-engineered and precision-manufactured for optimum performance in a variety of challenging cutting applications. The company says the end mills are durable and can provide 50 times more tool life than conventional carbide end mills.
CBN and PCD tools share a similar appearance and manufacturing process; however, the company says they are very different when considering their broad but divergent range of material applications.
PCD (Poly-Crystalline Diamond) is a matrix of randomly arranged diamond crystals, bonded to form a hard film or wafer. These diamond wafers are cut to the desired form for the end mill's cutting edge via a wire EDM process. The cut shapes are then permanently affixed to precision-manufactured carbide shanks through a microwave-brazing technique, which forms a bond able to withstand temperatures to 1,100°F. Finally, the finished cutting edges are precision-ground for added accuracy. The result, says the company, is an efficient tool for machining highly abrasive, non-ferrous materials, including graphite, high-silicon aluminum alloys, fiber-reinforced synthetics and copper alloys. These tools feature a "coolant-thru" design for efficient evacuation of dust and chips.
CBN (Cubic Boron Nitrate) wafers are formed through a sintering process; however, the remaining tool manufacturing process is nearly identical to that of PCD tools. CBN, says the company, is the hardest known substance next to diamond, and it provides the cutting edge for long-lasting end mills that are said to proficiently machine hard steels to 66Rc, as well as hard castings, Inconel, Monel and Stellite.
End mills are available from stock in ballnose, torus and flat-end designs, in sizes from 3/16" to 1/2 ". Metric sizes are also available, from 4 to 12 mm.