In the field of ultra-precision machining, processing hard and brittle materials like ceramics presents a unique set of challenges. Standard tools often fail to provide the necessary surface finish or tool life.
At More Super Hard, we specialize in overcoming these challenges. This case study highlights a recent solution: a custom-engineered PCD Solid Micro-Edge Milling Cutter designed specifically for high-precision ceramic applications.
Product Overview
This specialized tool combines the extreme hardness of Polycrystalline Diamond (PCD) with a unique micro-geometry. The multi-edge design (10 flutes) on such a small diameter (0.7mm) ensures exceptional stability and superior surface quality during the machining of abrasive ceramic materials.
Technical Specifications
Below are the detailed specifications of the manufactured tool:
|
Feature |
Specification |
|
Product Name
|
PCD Solid Micro-Edge Milling Tool
|
|
Tool Material
|
PCD (Tip/Edge) + Carbide (Shank) |
|
Workpiece Material
|
Ceramic |
|
Cutter Head Shape
|
Tapered (Cone) |
|
Number of Cutting Edges
|
10 Flutes (10T) |
|
Specific Model / Size |
D0.7 - R0.05 - 4 - 50 - d3H - T10 |
Decoding the Dimensions:
●Cutting Diameter (D): 0.7 mm
●Corner Radius (R): 0.05 mm
●Effective Cutting Length: 4 mm
●Overall Length: 50 mm
●Shank Diameter (d): 3 mm (H tolerance)
●Teeth (T): 10 Cutting Edges
Why This Design Matters
1. Material Compatibility: The PCD composition provides the necessary wear resistance to cut through abrasive ceramics without rapid edge degradation.
2. Micro-Geometry: The 0.7mm diameter coupled with a 0.05mm corner radius allows for extremely fine detail work and micro-machining.
3. High-Efficiency Finishing: Integrating 10 cutting edges on a micro-tool is a testament to advanced manufacturing capabilities. This high tooth count allows for higher feed rates and a smoother surface finish on the ceramic workpiece.
4. Tapered Design: The tapered cutter head shape enhances the rigidity of the tool, preventing deflection during the cutting process.
Our Expertise: More Super Hard
Manufacturing PCD tools with such microscopic dimensions and complex geometries requires mature technology and precise grinding capabilities.
More Super Hard possesses extensive experience in the production of PCD micro-edge milling tools and micro-drills. We understand that standard off-the-shelf tools often cannot meet the specific requirements of advanced manufacturing.
We offer:
●Customization: We can design and manufacture special shapes (tapered, ball nose, flat) based on your specific blueprints.
●Precision: Strict tolerance control ensures every micro-tool performs consistently.
●Versatility: Solutions available for ceramics, graphite, composites, and other hard-to-machine materials.
Looking for a Micro-Machining Solution?
If you need to machine complex geometries in ceramics or other hard materials, our engineering team is ready to assist.
Contact us today to discuss your custom PCD micro-tool requirements.
