NPD10, DA1090, & DABX Brochure

PCD CAT.NPD10DA1090.4/25

PCD Tools for Carbide and Hard Brittle Material Turning

SUMIDIA Binderless NPD10 / SUMIDIA DA1090 PCD PCD

SUMIDIA BINDERLESS PCD The ultimate in high-precision machining NPD10

SUMIDIA PCD higher-load machining DA1090

Coarse-grained polycrystalline diamond that takes on

SUMIDIA BINDERLESS PCD (NPD10) Small Diameter Boring Bars Ideal for high-precision machining of small diameters (ø.118” / ø3mm and up) Moving from electrical discharge machining to cutting reduces machining time and total costs DABX

SUMIDIA Binderless PCD SUMIDIA PCD NPD10 / DA1090

█ Application Range (Cemented Carbide)

100

NPD10 SUMIDIA Binderless PCD For Finishing

NPD10 Outstanding wear resistance under cemented carbide finishing conditions, suppressing dimensional variations. DA1090 Achieves stable tool life in machining of cemented carbide with sintered surface.

65

DA1090 SUMIDIA PCD

32

88HRA and above

Less than 88HRA

0

.004

.008

.012

.016

.020

Depth of Cut ap (in)

SUMIDIA BINDERLESS PCD NPD10

Cutting edge is 100% diamond material made from high-hardness nano-crystalline diamond which, unlike single-crystal diamonds, has no anisotropy. Achieves longer tool life and higher machining accuracy than conventional diamonds in the machining of cemented carbide and other hard brittle materials.

The outstanding wear resistance of nano-polycrystalline diamond enables high-precision machining of cemented carbides Ideal for Finishing of Cemented Carbide and other Hard Brittle Materials Compared to conventional diamond tools, the number of tool changes is drastically reduced, improving work efficiency and reducing total costs. Maintains Excellent Dimensional Accuracy for Long Periods

◦ Nano-Polycrystalline Diamond Nano-polycrystalline diamond is a polycrystalline diamond that directly binds nano-order diamond particles with high strength without using any binders. Harder than single-crystal diamond, it has no cleavability, enabling machining of hard brittle materials such as cemented carbide and making new machining methods possible.

◦ Hardness

Ultra-hard with no anisotropy Nano-polycrystalline Diamond

Single-crystal Diamond

Hardness depends on crystal orientation

Conventional PCD

Load 4.9N

0

Knoop Hardness HK (GPa) 50 100

150

2

SUMIDIA PCD / SUMIDIA Binderless PCD NPD10 / DA1090

█ SUMIDIA Materials

SUMIDIA PCD DA1000

SUMIDIA PCD DA2200

SUMIDIA PCD DA150

SUMIDIA PCD DA1090

SUMIDIA PCD DA90

SUMIDIA Binderless PCD NPD10

Grade

Structure

2µm

2µm

0.1µm

5µm

5µm

5µm

Diamond Particles

*White areas in the image are the binder material

Binder

-

Co

Co

Co

Co

Co

Grain Size (µm)

Up to 0.05

Up to 0.5

0.5

5

Up to 50

50

Content (%)

100

90 to 95

85 to 90

85 to 90

92 to 97

90 to 95

SUMIDIA PCD DA1090 A polycrystalline diamond material with the highest diamond content, made by sintering coarse diamond particles at high density.

High density and enhanced particle binding strength exhibit excellent wear and fracture resistance.

DA1090

Conventional PCD

2µm

2µm

30µm

30µm

Realizes high density and enhanced particle binding strength

*Black areas in image are diamond particles

Coarse-grain polycrystalline diamond with excellent wear resistance and enhanced particle binding strength improve fracture resistance, achieving stable machining in high-load roughing of cemented carbide and other hard brittle materials Ideal for Rough Machining of Cemented Carbide and Hard Brittle Materials

█ How to Use NPD10/DA1090 (Cemented Carbide Machining)

SUMIDIA Binderless PCD NPD10

SUMIDIA PCD DA1090

Grade

Dimensional Tolerance

Best

First Recommendation is NPD10

Tool Life (Wear Resistance)

Best

Applicable for ap=.008" or above

Machining Cemented Carbide with Sintered Surface

Not Applicable

Best

Machined Surface Quality

Best

First Recommendation is NPD10

3

SUMIDIA PCD / SUMIDIA Binderless PCD NPD10 / DA1090

¢ NPD10 Wear Resistance

Excellent wear resistance

.002 .004 .006 .008 .010 .012

After Cutting 1540ft

After Cutting 425ft

Conventional PCD

NPD10

● ● ●

■ ●

NPD10 ( V b =.001")

Conventional PCD ( V b =.007")

0

10

20

30

Cutting Time (min)

Workpiece Material: Cemented Carbide (87HRA) Insert: DCMA32.51RH Cutting Conditions: vc= 66 SFM f= .004 IPR ap= .004" Dry

¢ NPD10 Machining Accuracy

No change even after cutting time of 22 minutes.

No change even after cutting time of 55 minutes.

.0002 .0004 .0006 .0008 .0010

.0008 .0016 .0024 .0032 .0040

1.18”

1.18”

Conventional PCD

0 102030405060 ■■■■ ■ ■ ■ ■ ■ ■ ●●●●●●●●●●●●●●●●●●●● Conventional PCD NPD10

NPD10

0 5 10152025 Cutting Time (min) ■ ■●●■●●●●●●●●●●●●●●●●●●●

Cutting Time (min)

Workpiece Material: Cemented Carbide VC50 (87HRA) Insert: DCMA32.51RH Cutting Conditions: vc= 66 SFM f= .004 IPR ap= .004" Dry

Workpiece Material: Cemented Carbide VM30 (91HRA) Insert: DCMA32.51RH Cutting Conditions: vc= 66 SFM f= .002 IPR ap= .002" Dry

¢ DA1090 Wear Resistance

Excellent wear resistance under rough machining conditions

.002 .004 .006 .008 .010 .012 .014

DA1090

Conventional PCD

Damaged

Conventional PCD

● ●

■ ●

DA1090 Can Continue

■ ●

Large wear and flaking

Normal wear

■ ●

0

3

6

9

12

15

Cutting Time (min)

Workpiece Material: Cemented Carbide VM30 Equivalent (91HRA) Insert: NF-DCMA32.52 Cutting Conditions: vc= 98 SFM f= .002 IPR ap= .008" Dry

4

SUMIDIA PCD / SUMIDIA Binderless PCD NPD10 / DA1090

¢ Features Lineup of SUMIDIA Binderless Small Diameter Boring Bars for internal boring (ø0.12" - ø0.16" / ø 3 - ø 4mm )

The use of a high-rigidity shank design and nano-polycrystalline diamond tip enables finishing of cemented carbide

*For internal boring of ø.197" / ø 4mm or more, NPD10 inserts and indexable holders can also be used. Refer to the chapter on "Boring Bars" in the General Catalog for details.

Excellent Wear Resistance Keeps the Cutting-Edge Sharp

Wear resistance evaluation using cemented carbide (88HRA)

DABX

DABX

0.08

After Cutting 400 minutes

Machined Surface Roughness Rz 2.82µm

0.06

200µm

0.04

After Cutting 400 minutes

Workpiece Material: Cemented Carbide (88HRA) Insert: DABX035R-02 Cutting Conditions:

0.02

200µm

vc= 33 SFM f=.0016 IPR ap=.0012" Dry

0

100

200

300

400 Equivalent to machining 30 carbide molds

Cutting Time (min)

Minimal wear even after a cutting distance of 13,120ft

Cutting Reduces Machining Time and Total Costs

Switch from Electrical Discharge Machining (EDM) to Cutting

Cemented Carbide G5 (88HRA) Header Former Mold

2.5 Times the Machining Efficiency

Machining Time

90min

35min

 Cutting  Electrical Discharge Machining  Polishing

0 0.2 0.4 0.6 0.8 1.0 1.2

Costs reduced by 25%

Polished Surface Quality Rz = 0.3µm

Switching from EDM to Cutting Surface Roughness of EDM: Rz7.0µm Surface Roughness of Cutting: Rz1.3µm Reduces polishing time (Rz0.3µm) Achieves 2.5x Machining Efficiency with 25% total cost reduction

Polished Surface Quality Rz = 0.3µm

Machined Surface Quality Rz = 1.3µm

Machined Surface Quality Rz = 7.0µm

Electrical Discharge + Polishing

Cutting + Polishing

*Assuming ø4.0 → ø4.5 × L20 turning with machining costs at $22.50/hr, calculating tool life at 30 units/pc

5

SUMIDIA PCD / SUMIDIA Binderless PCD NPD10 / DA1090 ¢ Application Examples (Inserts) Cemented Carbide VC40 (89HRA) Die Mold Cemented Carbide VM70 (84HRA) Die Mold NPD10 achieves 5 times the tool life of competitors’ PCD NPD10 has 4 times higher machining efficiency and more stable dimensional tolerance than competitor’s PCD

.0002 .0004 .0006 .0008 .0010 .0012 .0014

15

Competitor's PCD

„

.787”

1.18”

„

10

„

„„

5

NPD10

„„ DDDDDDDDDDDDDDDD

0

8

16

24

0

Material Removal Volume (in 3 )

Competitor's PCD NPD10

Insert: CCMW03X102RH-NPD10, Internal Boring Cutting Conditions: N PD10 vc = 82 SFM f = .002 IPR a p = .002" Dry Competitors’ PCD v c = 16 SFM f = .001 IPR a p = .002" Dry

Insert: CCMW04X104RH-NPD10, Internal Boring Cutting Conditions: v c = 50 SFM f = .001 IPR a p = .003" Dry

Cemented Carbide VM30 (91HRA) Die Mold Alumina (99% pure) Machining costs reduced by 36% compared to conventional grinding by using DA1090 for roughing and NPD10 for finishing

NPD10 displays excellent wear resistance even on alumina material

100 Reduced 36%

.0008 .0016 .0024 .0032 .0040 .0048

Conventional PCD

‹

50

‹

NPD10

D

D

D D

DD

0 ‹

50 100 150

0

2.36”

Cutting Time (min)

Grinding DA1090 + NPD10

Insert: Roughing

NF-CCMA21.50.5-DA1090, Internal Boring

Insert: DNMA432RH-NPD10, External Turning Cutting Conditions: v c = 984 SFM f = .001 IPR a p = .001" Wet

Finishing CCMA21.50.5RH-NPD10, Internal Boring Cutting Conditions: Roughing v c = 66 SFM f = .004 IPR a p = .004" Dry Finishing v c = 66 SFM f = .0008 IPR a p = .0008" Dry

Cemented Carbide VF10 (93HRA) Carbide Pin NPD10 achieves 6 times the tool life of competitors’ PCD

Cemented Carbide VC70 (84HRA) Carbide Mold DA1090 reduces wear by 35% with excellent wear resistance

160

.018

120

.014

80

.010

40

.006

0 .002

0

Competitor's PCD NPD10

Competitor's PCD DA1090

Insert: DCMA32.50.5-NPD10, External Turning Cutting Conditions: vc = 100 SFM f = .0004 IPR ap = .004" Dry

Insert: NF-CCMA21.51-DA1090, Internal Boring Cutting Conditions: v c = 50 SFM f=.004 IPR a p =.004" Dry

6

SUMIDIA PCD / SUMIDIA Binderless PCD NPD10 / DA1090 ¢ Application Examples (Boring Bars) Cemented Carbide G5 (88HRA) Header Former Mold Cemented Carbide G5 (88HRA) Header Former Mold

DABX series displays excellent wear resistance in small-diameter machining of cemented carbide

Achieving more than 3x higher machining efficiency by switching from EDM to small-diameter cutting of cemented carbide

.0008 .0016 .0024 .0032 .0040

100

.945”

.787”

80

60

43% Reduction

DABX

90min

40

D D

D

0 20

D

Cutting DABX 20min

D

200

400

0

Electrode Machining + EDM

Equivalent to machining 30 pcs of carbide material

Cutting Time (min)

Insert: DABX025R-02 (NPD10) Internal Boring Cutting Conditions: v c = 33 SFM f = .002 IPR ap = .001" Dry

Insert: DABX035R-04 (NPD10) Internal Boring Cutting Conditions: v c = 33 SFM f = .002 IPR a p = .002" Dry

Cemented Carbide G2 (91HRA) Header Former Mold DABX series displays excellent wear resistance even in small-diameter machining of high-hardness cemented carbide

.0004 .0008 .0012 .0016 .0020 .0024

.787”

Able to continue

DABX

D D

D D

D

0

100 200 300

Cutting Time (min)

Insert: DABX035R-02 (NPD10) Internal Boring Cutting Conditions: v c = 33 SFM f = .002 IPR a p = .001" Dry

7

SUMIDIA PCD / SUMIDIA Binderless PCD NPD10 / DA1090 ¢ NPD10 Stock List Negative Inserts

Stock

Dimensions (inch)

Cutting Edge Length

Inscribed Circle

Corner Radius

Shape

Cat. No.

Thickness

Hole Dia.

NPD10

DNMA432RH DNMA433RH

.071 .071

.031 .047

D

.500

.187

.203

SNMA432RH SNMA433RH

.067 .067

.031 .047

 

.500

.187

.203

VNMA332RH VNMA333RH

.071 .059

.031 .047

 

.375

.187

.150

Positive Inserts

Stock

Dimensions (inch)

Cutting Edge Length

Corner Radius

Shape

Cat. No.

Inscribed Circle Thickness

Hole Dia.

NPD10

CCMW03X102RH CCMW03X104RH CCMW04X102RH CCMW04X104RH CCMA21.50.5RH CCMA21.51RH CCMA32.50.5RH CCMA32.51RH CCMA32.52RH DCMA21.50.5RH DCMA21.51RH DCMA32.50.5RH DCMA32.51RH DCMA32.52RH TPMA630.5RH TPMA631RH TPMA220.5RH TPMA221RH TPMA222RH TPMA330.5RH TPMA331RH TPMA332RH VCMA630.5RH VCMA630RH VCMA631RH VCMA220.5RH VCMA221RH VCMA330.5RH VCMA331RH VCMA332RH VCMA333RH

.051 .051 .067 .067 .067 .067 .067 .067 .063 .083 .079 .083 .075 .063 .047 .039 .059 .051 .039 .087 .079 .063 .087 .075 .059 .083 .067 .083 .067 .071 .059

.008 .016 .008 .016 .008 .016 .008 .016 .031 .008 .016 .008 .016 .031 .008 .016 .008 .016 .031 .008 .016 .031 .004 .008 .016 .008 .016 .008 .016 .031 .047

.138

.055

.075

D

 

.169

.071

.091

D D D D

.250

.094

.110

.375

.156

.173

   

.250

.094

.110

.375

.156

.173

D D

  

.187

.094

.091

.250

.125

.134

D

11°

    

.375

.187

.173

.187

.094

.091

D D

 

.250

.125

.110

D D

.375

.187

.173

 

8

SUMIDIA PCD / SUMIDIA Binderless PCD NPD10 / DA1090 ¢ DA1090 Stock List Negative Inserts NF type

Stock

Dimensions (inch)

Cutting Edge Length

Corner Radius

Shape

Cat. No.

Inscribed Circle Thickness

Hole Dia.

DA1090

NF-DNMA432 NF-DNMA433

.079 .079

.031 .047

 

.500

.187

.203

NF-SNMA432 NF-SNMA433

.094 .094

.031 .047

 

.500

.187

.203

NF-VNMA332 NF-VNMA333

.075 .067

.031 .047

 

.375

.187

.150

Positive Inserts NF type

Stock

Dimensions (inch)

Cutting Edge Length

Shape

Cat. No.

Corner Radius

Inscribed Circle Thickness

Hole Dia.

DA1090

NF-CCMA03X102 NF-CCMA03X104 NF-CCMA04X102 NF-CCMA04X104 NF-CCMA21.50.5 NF-CCMA21.51 NF-CCMA32.50.5 NF-CCMA32.51 NF-CCMA32.52 NF-DCMA21.50.5 NF-DCMA21.51 NF-DCMA32.50.5 NF-DCMA32.51 NF-DCMA32.52 NF-TPMA630.5 NF-TPMA631 NF-TPMA220.5 NF-TPMA221 NF-TPMA222 NF-TPMA330.5 NF-TPMA331 NF-TPMA332 NF-VCMA630.5 NF-VCMA631 NF-VCMA220.5 NF-VCMA221 NF-VCMA330.5 NF-VCMA331 NF-VCMA332 NF-VCMA333

.043 .043 .059 .059 .094 .094 .094 .094 .091 .102 .094 .102 .094 .079 .098 .094 .098 .094 .083 .098 .094 .083 .126 .110 .126 .110 .146 .130 .094 .083

.008 .016 .008 .016 .008 .016 .008 .016 .031 .008 .016 .008 .016 .031 .008 .016 .008 .016 .031 .008 .016 .031 .008 .016 .008 .016 .008 .016 .031 .047

                             

.138

.055

.075

.169

.071

.091

.250

.094

.110

.375

.156

.173

.250

.094

.110

.375

.156

.173

.187

.094

.091

.250

.125

.134

11°

.375

.187

.173

.187

.094

.091

.250

.125

.110

.375

.187

.173

¢ ALNEX ANX series Blade Stock List

Stock

Cutting Edge Length (Inch)

Wiper Flat Shape

Shape

Cat. No.

Applications

DA1090

ANB1600R-GB

.236

Arc-Shaped Bi-metal Milling*

*Cast Iron/Aluminum Alloy For details on the ANX series cutter body, see CAT.ALNEX.10/19 brochure and the General Catalog.

9

SUMIDIA PCD / SUMIDIA Binderless PCD NPD10 / DA1090

SUMIDIA Binderless PCD Brazed

Binderless

93˚

%"#9 *OUFSOBM#PSJOHBOE'BDJOH

Min. Bore Dia. (DMIN)

Fig 1

DCON

RE

LF

HF

¢ DABX series Boring Bar Stock List

Dimensions ( mm )

Stock Min. Bore Dia.

Diameter

Cutting Edge Distance Overall Length Corner Radius

Applicable Sleeves

Cat. No.

Fig

DMIN

DCON

HF

LF

RE

3 3 3 4 4 4

2.5 2.5 2.5 3.5 3.5 3.5

1.25 1.25 1.25 1.75 1.75 1.75

40 40 40 40 40 40

0.1 0.2 0.4 0.1 0.2 0.4

HBX2516 1 HBX2516 1 HBX2516 1 HBX3516 1 HBX3516 1 HBX3516 1

DABX025R-01 DABX025R-02 DABX025R-04 DABX035R-01 DABX035R-02 DABX035R-04

     

DABX bars can be used with HBB sleeves, but HBX sleeves are recommended for machining when rigidity is required.

Fig 1

Fig 2

DCB

ø16

DCB

15 15

100

15

100

¢ Sleeves (HBX)

¢ Sleeves (HBB)

Dimensions ( mm )

Dimensions ( mm )

Bore Dia.

Bore Dia.

Applicable Boring Bar

Applicable Boring Bar

Cat. No. Stock

Fig

Cat. No. Stock

Fig

DCB

DCB

2.5 3.5

DABX025R 1 DABX035R 1

2.5 3.5

DABX025R 2 DABX035R 2

HBX2516 HBX3516

HBB2516 HBB3516

 

 

¢ Parts (for Adapter Sleeve)

Flat Screw Set Screw Wrench

TRD

BT06035T

Applicable Sleeve

N m

LH

BT0404

1.5 BT06035T TRD15 3.0 BT06035T TRD15

HBX 2516 HBX 3516

BFTX0409N BFTX0409N

HBB SSSS

BT0404 LH020

Q

Q

10

SUMIDIA PCD / SUMIDIA Binderless PCD NPD10 / DA1090

¢ Recommended Cutting Conditions

Workpiece Material

Cutting Conditions

Grades

Classification Hardness (HRA)

Our Grades

Cutting Speed vc (SFM)

Feed Rate f (IPR)

Depth of Cut ap (in)

VM,VC 40

88 or more

G5,D2

15 - 100

.001 - .003

.001 - .003

NPD10

VM,VC 70,60,50 83 to less than 88

G7,G6

15 - 100

.001 - .008

.001 - .008

VM,VC -

83 or more G7,G6,G5,D2

15 - 100

.001 - .008

.001 - .020

DA1090

Min. - Max. Lubrication: Dry

¢ Application Range for NPD10 and DA1090

¢ Application Range for DABX series Boring Bars

.020

DA1090

.0040

.016

.0032

.012

Less than 88HRA

.0024

NPD10

.008

.0016

Less than 88HRA

NPD10

88HRA and above

.004

.0008

88HRA and above

.004

0 .002

.006 .008

0 .0008 .0016 .0024 .0032 .0040

Feed Rate f (IPR)

Feed Rate f (IPR)

* Carbide shanked holders are recommended for internal boring.

11

NPD10 P RODUCT P AGE

DA1090 P RODUCT P AGE

Sumitomo Electric Carbide, Inc. Headquarters 1001 Business Center Drive Mount Prospect, IL 60056-2181 Phone: (847) 635-0044

Sumitomo Carbide Canada, Inc. 150 Research Lane, Unit 210 Guelph, Ontario N1G 4T2 Canada

Phone: (519) 265-6050 Phone: (844) 211-6050

Americas Tool Engineering Center A-TEC

5637 S. Westridge Drive New Berlin, WI 53151

Michigan Branch 26800 Meadowbrook Suite 120 Novi, MI 48377

595 S. Emerson Avenue Suite 100 Greenwood, IN 46143 Indiana Branch

WWW.SUMICARBIDE.COM

CAT.NPD10DA1090.4/25

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