Recently, a client in the high-end display and semiconductor sector approached us to optimize their quartz glass machining process. The material's extreme hardness (Mohs 7) was causing rapid tool wear and unacceptable surface finish issues with their original tooling supplier.
3. Performance Comparison: Original Solution vs. MORE SUPER HARD
We deployed our custom-engineered PCD Micro Edge Milling Tool (D8). The cutting parameters were kept identical to prove the superiority of our tool geometry and material.
|
Machining Parameters |
Original Solution |
MORE SUPER HARD Solution |
|
Tool Type |
PCD Micro Edge Mill |
PCD Micro Edge Mill |
|
Specification |
Ø 8 mm |
Ø 8 mm |
|
Tool Material |
Standard PCD |
Premium Selected PCD |
|
Depth of Cut (ap) |
0.005 mm |
0.005 mm |
|
Width of Cut (ae) |
6 mm |
6 mm |
|
Spindle Speed (RPM) |
20,000 r/min |
20,000 r/min |
|
Cutting Speed (Vc) |
500 m/min |
500 m/min |
|
Feed Rate (f) |
0.025 mm/rev |
0.025 mm/rev |
|
Surface Roughness (Ra) |
0.06 μm (Visible tool marks) |
0.03 μm (Mirror-like finish) |
|
Tool Life (Pieces) |
50 pcs |
150 pcs (+200% Increase) |
4. Why Our PCD Tools Win: Scheme Analysis
By switching to MORE SUPER HARD's PCD Micro Edge Series, the client achieved a massive upgrade in three critical areas:
A. Flawless Surface Quality (Ra 0.03 μm)
Quartz glass is highly susceptible to micro-cracks during milling. The original tool left obvious machining lines (Ra 0.06).
● Our Advantage: Our PCD end mills feature specially designed edge parameters processed by an ultra-precision laser machining technology. This ensures the cutting edge is perfectly intact yet razor-sharp. As a result, we eliminated the visible tool marks, upgrading the surface roughness directly to Ra 0.03 μm—a full grade higher in surface quality.
B. 3X Extended Tool Life
The extreme brittleness and Mohs 7 hardness of quartz glass lead to rapid abrasive wear on standard tools.
● Our Advantage: We utilize rigorously selected, high-grade Polycrystalline Diamond (PCD) materials with exceptional wear resistance. Even under 20,000 RPM high-speed conditions, our tool successfully machined 150 pieces compared to the competitor's 50 pieces, extending the tool life by 3 times.
C. Maximum Machining Efficiency & ROI
Our ultra-fine micro-edge series is developed specifically for hard and brittle materials.
● Our Advantage: The tools feature an ultra-high flute density (dense tooth design), enabling high-efficiency material removal. By tripling the tool life, we drastically reduced the frequency of tool changes and machine downtime. This directly lowers the cost-per-part and significantly enhances the market competitiveness of our semiconductor and high-end manufacturing clients.
Are you struggling with edge chipping, short tool life, or poor surface finishes when machining Quartz, Silicon, or Ceramics?
At MORE SUPER HARD, we engineer custom PCD micro-milling solutions that turn impossible materials into routine production. Contact our engineering team today to optimize your hard and brittle material machining process.
