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
7°
.250
.094
.110
.375
.156
.173
.250
.094
.110
7°
.375
.156
.173
D D
.187
.094
.091
.250
.125
.134
D
11°
.375
.187
.173
.187
.094
.091
D D
.250
.125
.110
7°
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
7°
.250
.094
.110
.375
.156
.173
.250
.094
.110
7°
.375
.156
.173
.187
.094
.091
.250
.125
.134
11°
.375
.187
.173
.187
.094
.091
.250
.125
.110
7°
.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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