PCD Carbide Profiling Milling Tools For Si Aluminium alloys High-Speed Machining

Introduction:

For high-speed machining (HSM) of silicon-aluminum (Si-Al) alloys (e.g., AlSi7, AlSi12, AlSi17), PCD (Polycrystalline Diamond) profiling milling tools are the optimal choice due to their extreme wear resistance and ability to maintain sharp cutting edges.

Features:

1. Why PCD for Si-Al Alloys?

• High Silicon Content (>12% Si) causes rapid tool wear in carbide tools. PCD outperforms due to diamond’s hardness.

• High Cutting Speeds (500–5,000+ m/min) possible, improving productivity.

• Long Tool Life (5–10x longer than carbide), reducing tool changes.

• Superior Surface Finish (Ra < 0.4 µm achievable).

PCD Profiling Milling Tool Designs

(a) End Mills (Solid PCD or Indexable Inserts)

• 2–6 Flutes (higher flute count for finishing, fewer for roughing).

• Helix Angle (30°–45°) for chip evacuation and reduced cutting forces.

• Variable Pitch to minimize vibration in high-speed machining.

(b) Contour/Profile Mills

• Ball-Nose PCD for 3D profiling (e.g., aerospace components).

• Corner Radius Tools for durability in high-feed machining.

(c) Indexable PCD Face Mills

• For large-area machining (e.g., engine blocks, cylinder heads).

• Multi-tooth designs (e.g., 6–10 inserts) for high MRR (Material Removal Rate).

Applications

• Aerospace: Machining aluminum fuselage parts, titanium, or CFRP (carbon fiber reinforced polymers).

• Automotive: Engine blocks (silicon-aluminum alloys), brake discs, and transmission components.

• Electronics: Precision milling of copper, graphite electrodes, or ceramic substrates.

• Woodworking/Composites: Cutting abrasive laminates, MDF, or fiberglass.

Detailed Pictures:

Our workshop:

Our Advantages:

1.Advanced grinding machines: All of our grinding machines are WALTER and SAACKE brands.

2. Advanced inspection machines: We have ZOLLER, OMEGA, PG1000, etc. For inspecting each carbide tools.

3.Highly skilled design team: We are specialized in producing complicated customized carbide tools and we can design the carbide tools according to the work pieces.

4.Fast feedback: we offer 24 hours online service

5.Strict quality control system:

We strictly adhere to a three-stage inspection process for each tool:

Raw material inspection

Semi-finished product inspection after production

Final inspection after coating (pre-shipment check)

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