Composites & Carbon Fiber composites are essential raw materials widely used to manufacture strong and lightweight products. These are manufactured by the merging of two or more different materials to result into something better and new. Machining composites and CFPR poses a problem for manufacturers due to it?Structure, Stay with me on this!. This can be a challenging process as these materials are hardened and can be abrasive to cutting devices. That’s where the Carbide Inserts coated in diamonds come into play!

Brief introduction of composite and CFRP material:

Composites are a combination of at least two different materials. This produces a material that has the positive and negative characteristics of each of the materials, but also has new characteristics that make it better than the original materials alone. CFRP – Carbon Fiber Reinforced Polymer A composite material made of carbon fibers and polymer resin. Which makes a very strong and light material - one that’s great for everything from aerospace to cars to sports equipment.

Advantages of Diamond coated carbide inserts used in machining of abrasive materials:

Traditional cutting tools wear out as well become dull fast when machining abrasive materials such as composites and CFRP. This results in lots of waste when cutting, automatic tool breakage and the low efficiency. And this is where diamond-coated carbide inserts are invaluable. The diamond coating of this wear-resistant insert is hard enough to optimize resistance to wear, while stable enough to withstand extreme temperatures. These Threading Inserts have a longer life compared to conventional cutting tools which leads to lower cutting forces cutting performance and productivity.

Approaches to enhance the cutting ability in adverse conditions:

CUTTING PERFORMANCE OF DIAMOND COATED CARBIDE INSERT The correct cutting parameters are very important for maximizing the cutting performance of diamond coated carbide insert in difficult-to-machine material conditions such as this. This includes stuff like cutting speed, feed rate, and depth of cut. With this knowledge in hand, tool producers are able to get their cutting tools running in top form and kick out high-quality parts. Moreover, it is possible to reduce heat and friction by applying coolant or lubricant in the cutting process so as to maintain longer life for the cutting tools.

Durability and performance in abrasive machining:

The dirty is, prolonged service life and use of diamond-coated carbide insert during abrasive machining is ensured, if the cutting tools are handled with caution. This involves periodically cleaning and inspecting the inserts and, as needed, sharpening or replacing inserts that have become dull or damaged. And using proper tool holders and workholding fixtures can minimize vibration and enhance cutting accuracy. Properly maintaining and running the cutting tools ensures that manufacturers can benefit from the longest and most efficient possible tool life.

Diamond-coated carbide insert case studies, which shows the success of these inserts:

NIGEL the cutting tool manufacturer has carried out a number of case studies to show how much diamond coated carbide inserts can improve productivity and reduce total tool costs when cutting abrasive materials. In one research, these inserts were utilized by NIGEL to cut CFRP components for the aerospace sector. It was revealed that the inserts significantly outperformed conventional cutting tools in terms of its duration before being worn out, thus leading to a time and cost savings to the manufacturer.

An alternative study for NIGEL was the machining of composites for the automotive industry using diamond coated carbide inserts. Inserts could create first-rate parts with aesthetic, smooth appearances, which help minimize the post processes and finishing work needed. This served to enhance the total productivity of the production process, and to increase the profitability of the producer.

In conclusion, CBN coated carbide inserts are an excellent choice for machining materials which are hard and abrasive such as composites and CFRP. Such cutting tools can result in enhanced cutting performance, longer tool life, and more efficient machining in difficult cutting conditions. With the appropriate cutting parameters, conditions and strategies, your operation can take full advantage of your diamond-coated carbide inserts. NIGEL is pleased to present a full range of diamond PCD Turning Inserts that can be used to tackle difficult machining challenges and ultimately provide a superior, highly successful solution to your project.