– Material: Different materials require different cutting-speeds. Always refer to recommended cutting speed charts based on the material of the workpiece and the tool.

Cutting-speed is a critical parameter in machining processes for several reasons, impacting tool life, surface finish, production efficiency, and overall machining quality. Here are the key reasons why cutting speed is important:

By using these formulas and considering the practical aspects, machinists can determine the optimal cutting speed for their specific machining conditions.

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Cutting speed, is a critical parameter in machining processes that refers to the speed at which the cutting tool passes over the surface of the material being cut, it is also known as surface speed.

– Tool Material: The cutting tool material also affects the optimal cutting-speed. Carbide tools can usually handle higher speeds than high-speed steel (HSS) tools.

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When using PCD polycrystalline diamond tipped tools, it is crucial to consider all the application details, machining parameters, and expectations to ensure the tool is appropriate for the application. Compression bits can perform differently over their lifetime, even if they are purchased simply.

The production of polycrystalline diamond, or PCD, occurs synthetically by sintering together many particles of diamond, usually 2 to 30 microns in size, with a metal binder (usually cobalt) under high pressure and temperature.

There may be 90-95% diamond particles in PCD, and the rest is the binder. PCD is commonly used in cutting tools to cut through composite materials and super hard metals to extend the tool life.

In order to make diamond tools affordable for even the smallest cabinet shop, some router bits are designed as “disposable”, i.e. the tip height is about 3mm, which will allow no more than 1 sharpening before the tool must be retired. Other tools might have a 4 or 5mm tip height, which will provide sufficient tip size to sharpen the tool several times. The disposable design tools are usually designed with a carbide-tipped plunge point, as it will generally not wear out before the tool is retired. These are all considerations to be aware of when shopping for diamond tools. It can be difficult for the layman to truly compare product and expected performance.

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By setting the cutting speed to the recommended 150 m/min, the machinist can achieve a balance between efficient material removal, good surface finish, and extended tool life, optimizing the overall machining process.

Depth of Cut (d): The distance the cutting tool penetrates below the original surface of the workpiece during machining,

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Wear resistance It is second only to pure diamonds. As a result of its hardness, the material can withstand wear and tear in any application that involves abrasive materials. Wear rate is influenced by workpiece material and cutting speed. Among composites, MMC, CMC, and high silicon aluminum, PCD has a significant wear rate advantage over cemented carbide.

If the machinist sets the speed significantly lower than this (e.g., 50 m/min), the tool might wear out prematurely due to built-up edge formation, and the surface finish could be poor.

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Several factors influence the cutting-speed in machining operations, each playing a significant role in determining the optimal speed for a given situation. Here are the key factors:

TRS (Transverse Rapture Strength) Compared to metals, PCD is a brittle and less tough material. Different grain sizes of PCD materials have different TRS. A PCD material with a smaller grain size has a higher TRS than one with a larger grain size.

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Hardness With a metal binder, its hardness ranges between 6500-7500 HV, which is close to pure diamond’s hardness of 10,000 HV.

Conversely, setting it too high (e.g., 300 m/min) could cause excessive heat, leading to rapid tool wear or even tool failure.

Many of the popular PCD compression bits have a staggered tooth design (as shown below) and are described in terms such as “Z1+1”, “Z2+2” or “Z3+3”. What this means in laymen’s terms is that, with a Z1+1 for instance, you only have one flute cutting. In this example, 1+1 does not equal 2. It means one section of the tips is shearing downward, and one is shearing upward. With a single flute diamond tool, machine feed speed will be limited to no more than 200″/minute, so for most shops, a Z2+2 will be more suitable.

Jul 19, 2021 — Drill bit size chart provides a list of sizes in several measurement systems, including fractional, metric, wire gauge number, and letter.

Consider machining a mild steel part using a carbide tool. The recommended cutting speed for mild steel with a carbide tool might be around 150 m/min.

An all-purpose PCD tool does not exist. General Cutting Tools can provide expertise and give a very specific offer, exactly defined for your application. This method guarantees a most economic result when using PCD tipped tools.

Cutting speed definition (Vc): The speed at which the material is removed by the cutting tool. It is the tangential speed of the workpiece surface relative to the cutting tool.