Diamond Cutting Tools AL1 to AL13 AL AL
For Cylinder Head Cutting PCD Rotating Tools ............................. AL2 For Valve Guide Hole Cutting PCD Rotating Tools ............................. AL4 For Valve Body Cutting PCD Rotating Tools ............................. AL5 For Steering Part Cutting PCD Rotating Tools ............................. AL7 For Cemented Carbide Glass Lens Molds Ultra-precision Cutting Tool BLPCD UPC .. AL9 For Various Mold Machining (Spherical/Non-Spherical, Camera Lens Molds, etc.)/For Various Mold Machining (Infrared Lens Molds, etc.) Ultra-precision Cutting Tool UPC-R ........ AL10 For Optical Shim Mold Machining, etc. Ultra-precision Cutting Tool UPC-Nano Groove ......... AL11 For Micro Lens Array Mold Machining, etc. Ultra-precision Cutting Tool UPC-Nano Ball Endmill ......... AL11 For LCD Light Guide Plate Mold Machining, etc. Ultra-precision Cutting Tool UPC-Nano Endmill ........ AL12 For Optical Shim Mold Machining, etc. Ultra-precision Cutting Tool UPC-Nano Profile ........ AL12 For Glasses Lens Roughing PCD Face Milling Cutters .................. AL13 For Glasses Lens Finishing New D Holders .................................. AL13
Diamond Cutting Tools
AL1
For Cylinder Head Cutting PCD Rotating Tools
Automotive Components
Features A single reamer can finish multi-stage holes, reducing work processes. Delivering an excellent surface finish unobtainable with carbide tools. Precise and stable dimensional and shape accuracy unique to diamond tools can be maintained for a long time. Cutting speed and feed can be tuned to reduce machining time. D D D D
AL
High-precision / high-efficiency machining is realised through high-quality cutting edge accuracy created by diamond precision machining technology. Data 2: Good Balance between High-efficiency Cutting and High Machining Accuracy
Data 1: Improved Productivity due to Breaking Chips
Negative Land Specification Cutting Edge
Shim Fitting Hole
The chipbreaker function has been enhanced to prevent a reduction in productivity due to problems caused by chips. Solutions are proposed according to the type of chip problem.
Valve Guide Hole
Without Chipbreaker
Work Material Drawing
Machining Diagram
1 Flute 52 Results Machining Time ( s ) Circularity ( mm ) Coaxiality ( mm ) D Difference in Performance by Shank Material 0.01 0.01 4 Flute (Steel) 26 0.05 0.07 4 Flute (Cemented Carbide) 13 0.03 0.05
Long chips formed without curl. · Wrapping around tool · Remains on workpiece
With Chipbreaker
D Cutting Conditions
Machine Tool Size (mm) Work Material Coolant
Horizontal Machining Centre ø 11 to ø 36 to L150 Aluminum Alloy Castings AC4B Emulsion-type water-soluble oil 3,500 395
Chips are forcibly curled and break into small pieces.
Spindle Speed (min -1 ) Cutting Speed (m/min) Feed Rate (mm/rev) Allowance ( mm/ diameter)
0.3 0.5
AL2
For Cylinder Head Cutting PCD Rotating Tools
Automotive Components
Tool Lineup for Cylinder Head Machining
PCD Reamer for Solenoid Hole Machining Multi-blade/multi-stage high-precision reamers ensure coaxial accuracy. hining
PCD Reamer for Spark Plug Hole Machining High-precision coaxial machining is realised by increasing the number of teeth at the machining start section (second stage).
AL
PCD Cutter for Cam Grooving Staggered blades are used to lower cutting resistance and achieve high-precision grooving with less chatter.
PCD Reamer (1- ute) for Valve Lifter Hole Machining
Guide pad design with attention to rotation balance realises high-precision hole nishing.
PCD Reamer for HLA Hole Machining Special 2 blade design can handle large lateral holes, preventing cutting edge drops.
PCD Endmill for Spring Shim Machining Cutting edges has a chipbreaker function, preventing chips from entering the water jacket. ning
Improves chip evacuation and achieves a high cylindricity using a design ideal for machining of thin-wall parts and blind holes. Finishing
D Cutting Conditions Machine
Horizontal Machining Centre
PCD Ball Endmill
Coolant
Emulsion-type water-soluble oil
for Cam Half-Rounding The use of PCD increases machining accuracy and reduces machining load in later processes.
Spindle Speed (min -1 )
5,000
Feed Rate (mm/min)
1,700
0.34
Feed Rate (mm/rev)
0.5
Allowance (mm/diameter)
*HLA: Abbreviation for hydraulic lash adjuster
PCD Reamer for Cam Sensor Hole Machining The cutting force is reduced, improving the cutting speed and accuracy. r
PCD Reamer for Parent Metal Hole Machining The use of a high-rigidity body enables high-coaxial nishing of guide holes and shim holes before press- tting.
PCD Endmill for Valve Throat Machining Simultaneous roughing of the parent metal insert section and throat machining.
Achieves a good balance between coaxiality and cylindricity with a high rigidity shank and high cutting edge precision. Parent Hole Finishing
D Cutting Conditions Machine
Horizontal Machining Centre
Coolant
Emulsion-type water-soluble oil
PCD Endmill for Valve Throat Machining Achieves longer tool life in throat machining through high-precision runout and contour accuracy.
Spindle Speed (min -1 )
6,000
Feed Rate (mm/min)
2,880
0.48
Feed Rate (mm/rev)
0.6
Allowance (mm/diameter)
AL3
For Valve Guide Hole Cutting PCD Rotating Tools PCD Rotating Tools For Valve Guide Hole Cutting
Automotive Components
Because the valve guide uses sintered alloy and cast iron, the use of a reamer with a cemented carbide cutting edge shortens the tool life and increases the frequency of tool exchange, decreasing machining efficiency. In valve guide hole machining, because the cutting speed is slow with hole diameter around 5mm, a diamond cutting edge with high wear resistance is superior to cemented carbide in cutting edge sharpness sustainability and tool life. We propose high-precision, high-efficiency machining through tool design in accordance with the required quality and cutting conditions.
AL
Features D Tool life is around 10x that of carbide tools. D High-precision and high-efficiency machining can be achieved.
PCD Valve Guide Reamer for 4 flute Finishing Fine-pitch, rigid tool design realises high-feed machining.
PCD Valve Guide Reamer for 1 flute Pilot Machining Used for high-precision finishing of prepared holes. High-efficiency fine-pitch designs are also available. PCD Valve Guide Reamer for 1 flute Finishing This finishing tool has a leading edge that fits the pilot hole. Achieves high-precision machining with a high-rigidity body.
PCD Valve Guide Reamer with Helix Angle for 4 flute Finishing High-quality valve guide hole machining is enabled with a negative helix angle cutting edge, making it easier to evacuate chips in the feed direction.
Viewpoint Angle: 270,000°
Eccentricity
Magnification: Actual Size
Cylindricity CY = 1.7µm
Circularity P-P = 0.6µm
Axial Concentricity (Z) SOA = 2.2μm
Linearity 2.2 μm
Cylindricity 1.7 μm
Circularity 0.6 μm
AL4
For Valve Body Cutting PCD Rotating Tools
Automotive Components
Valve body spool hole machining is one of the most dif cult types of machining. Hole nishing, which involves both interrupted cutting and multi-stage machining, requires high machining accuracy in quality issues such as surface roughness, circularity, cylindricity, and coaxiality. A.L.M.T. proposes ideal tool designs based on various machining experience.
Features D A single reamer can nish multi-stage holes, reducing work processes. D Delivering an excellent surface nish unobtainable with carbide tools. D Precise and stable dimensional and shape accuracy unique to diamond tools can be maintained for a long time. D Cutting speed and feed can be tuned to reduce machining time.
AL
Tool Lineup for Valve Body Machining
1 ute 4-stage PCD Reamer Single- ute multi-stepped design realizes high circularity and coaxiality.
4 ute 4-stage PCD Reamer with Leading Edge With a leading edge added to each cutting edge, position deviation from the previous process is prevented, the result is high-precision hole nishing at high feed conditions.
4 ute 3-stage PCD Drill Medium nishing for pre-cast hole drilling, high feed and high-accuracy prepared hole drilling are possible.
5 ute Irregular Pitched 3-stage PCD Reamer With irregular pitched cutting edges,
2 ute 4-stage PCD Drill Medium nishing for deep hole drilling, multi-step machining improves nished coaxiality.
vibration (resonance) during machining is suppressed and circularity and cylindricity are improved.
Various additional function proposals
Close-up
Close-up
Close-up
Chip evacuation function Single cutting edge with a chip discharge groove in the guide pad section prevents adhesion to the cutting edge, thus preventing quality deterioration.
Chip breaking function Addition of a chip breaking function to the cutting edge prevents quality deterioration due to machining defects and machine stoppage due to chip entanglement onto the holder.
Workpiece chipping prevention function The area around the hole exit is weak, cutting forces may cause chipping of the workpiece along with chips or ring-shaped chips that can wrap around the workpiece. This can be prevented by a cutting edge design that suppresses cutting resistance.
AL5
For Valve Body Cutting PCD Rotating Tools
Automotive Components
Valve Body Application Examples
PCD Reamer Cemented Carbide Reamer 120
Functions
Cutting Speed Feed Rate Allowance Coolant Machined Surface Roughness Circularity Economic Efciency Ratio
120 0.2 0.4 Non-water-soluble Cutting Oil 8 3 to 6 1
(m/min) (mm/rev) (mm/dia.)
0.2 0.4 Water soluble 3 1 to 3 0.5
Rz (μm) (μm)
AL
Work Shape
Proposals for High-speed Feeds and Chatter Reduction with Irregular-pitched Reamers D Using an irregular pitch design that focuses on rotational balance prevents resonance due to cutting resistance and cutting edge biting inside the hole, enabling high-precision machining. D The above results in suppressed chatter as well as improved circularity and cylindricity. D In comparison to 1-ute machining, even at the same speed, multi-ute machining enables higher feed rate and thus reduces machining time.
Application Examples
1 ute Balance Specication
4 Flutes
4 ute Irregular Pitch 5 ute Irregular Pitch
Shape
(mm/dia.) (min -1 ) (mm/min) (mm/rev) (mm/z)
0.5 to 0.7 1,000
0.5 to 0.7 1,000
Allowance Spindle Speed Feed Rate
960 0.24
400 0.1 0.1
0.05 960 0.24
Feed Rate per Revolution Feed Rate per Cutting Edge
0.06 Emulsion-type water-soluble oil
Emulsion-type water-soluble oil
Coolant Chatter Cylindricity
No 6
Yes 6
No 4
No 3
(μm)
Magnication: Actual Size
*Image only.
Cylindricity 3 μm
Coaxiality 1 μm
AL6
For Steering Part Cutting PCD Rotating Tools
Automotive Components
In recent years, aluminum steering parts have become lighter, and there is a demand for shorter machining time at higher feed rates. Our proprietary tool design achieves both reduced machining time and high machining quality.
Features D A single reamer can nish multi-stage holes, reducing work processes. D Delivering an excellent surface nish unobtainable with carbide tools. D Precise and stable dimensional and shape accuracy unique to diamond tools can be maintained for a long time. D Cutting speed and feed can be tuned to reduce machining time.
AL
Tool Lineup for Steering Housing Machining g p
4 ute 8-stage PCD Reamer Multi-blade/multi-stage PCD reamers with high-precision nishing for excellent coaxial machining.
5 ute Irregular Pitched PCD Reamer Irregularly pitched 5 ute design suppresses chatter to improve deep hole circularity.
4 ute Irregular Pitched PCD Reamer with Interface Structure with interface realises high rigidity, high feed, and high-precision machining. Cutting Edge Indexable PCD Mill for Facing Opening facing with 1 ute and corner insert method reduce tool running costs.
4 ute + 5 ute Irregular Pitched PCD Reamer With a design that uses a different arrangement for each step of the cutting edges, vibration (resonance) in machining is prevented thus creating high-precision machining.
4 ute Blade for Peripheral Machining PCD Endmill Inner blade design keeps machining distance short, enabling protrusion plunging or contouring, so that machining time can be reduced.
5 ute + 3 ute PCD Reamer PCD 5 ute cutting edge and PCD 5- ute guide improve circularity, with 3 utes at opening to suppress chatter.
Proposals for Reducing Processes with Combination Tools
Combination of Back Spot Facing and Reamer Drilling and back spot facing can be machined with a single tool. Contouring is performed with offset from axis of rotation.
Combination of Threading (indexable) and Grooving Three processes (tapping + grooving + reaming) are integrated into a single tool, reducing tool change time and number of tools required.
Combination of Face Grooving and Back Boring Process is reduced by shifting off-center of the prepared hole to perform back boring, after the front face grooving operation. Boring diameter is adjustable.
Combination of Endmill with Central Insert and Reamer
By nishing the bottom face during the reaming process, machining time can be reduced while improving bottom face diameter, atness and surface roughness.
AL7
For Steering Part Cutting PCD Rotating Tools
Automotive Components
Proposals for High-speed Feeds and Chatter Reduction with Irregular-pitched Reamers
Features D Extremely effective for improving chatter prevention, cylindricity, and circularity. D Cycle time can be shortened by a third compared to the use of 4 utes. D Design with attention to rotating balance.
AL
5 ute Irregular Pitched Reamer
Application Examples
4 ute Regular Pitch 4 ute Irregular Pitch
5 ute Irregular Pitch
Shape
Allowance
(mm/dia.)
0.5 to 0.7
0.5 to 0.7
Spindle Speed
(min -1 )
1,000
1,000
400
400
125
Feed Rate
(mm/min)
0.4
0.4
Feed Rate
(mm/rev)
0.125
Emulsion-type water-soluble oil
Emulsion-type water-soluble oil
Coolant
Yes
No
Chatter
24
18
8
4
Circularity
(μm)
AL8
For Cemented Carbide Glass Lens Molds Ultra-Precision Cutting Tool BLPCD UPC
Optical Components
Achieves long tool life in mirror nish and ne machining of cemented carbides SUMIDIA BINDERLESS is a new material developed by Sumitomo Electric Industries, Ltd. Fine grains of a few tens of nanometres are rmly and directly bonded together without the use of a binder, achieving a hardness exceeding that of single crystal diamond. There is also no anisotropy or speci c cleavage. Combined with our signature diamond precision grinding technology, this material enables unprecedented tool life and chipping resistance.
Features [Features of SUMIDIA BINDERLESS] D Fine grains of a few tens of nanometres are rmly and directly bonded
together without the use of a binder. D Harder than single-crystal diamond. D No anisotropy or speci c cleavage.
AL
[Features of BLPCD UPC] D Superior fracture and wear resistance compared to single/polycrystalline diamond. D Sharp and precise cutting edge equivalent to UPC (single-crystal diamond). D Free from uneven wear caused by crystal orientation, as it is not anisotropic.
Applications D Machining of cemented carbide glass lens molds and other high-hardness and brittle materials
Flank Wear Comparison of Machined Cemented Carbide
Sharp Cutting Edge Equivalent to Single Crystal Diamond
Wear Damage
Chipping
0.025mm
0.025mm
BLPCD UPC
UPC (Single-crystal Diamond)
50μm
No Large Chipping Found
Large Chipping Found
Surface Roughness of Machined Cemented Carbide
500μm
Ra 3.5nm
*"SUMIDIA" is a registered trademark of Sumitomo Electric Industries, Ltd.
AL9
For Various Mold Machining (Spherical/Non-Spherical, Camera Lens Molds, etc.)/For Various Mold Machining (Infared Lens Molds, etc.) Ultra-Precision Cutting Tool UPC-R Optical Components
Ultra-precision Cutting Tool UPC-R For Various Mold Machining (Spherical/Non-Spherical, Camera Lens Molds, etc.)
Exhibits outstanding performance in ultra-precision cutting An ultra-precision cutting tool for machining of molds used for products like spherical/aspherical lenses and camera lenses where extremely high precision is called for. Our proprietary development process yields high-precision polished blades which realise microscopic shaping of workpieces with high precision on the nanometre level.
Features D The cutting edge is uniformly nished in high quality, achieving nanometre-level surface roughness. D An inspection report of the cutting edge arc waviness is attached to the product for thorough quality control. Applications D BD pickup lens molds, digital camera lens molds, camera lens molds for smartphones/computers/tablets, spherical/aspherical mirrors, etc.
AL
Close-up of Cutting Edge
Cutting Edge Shape
40° L
Cutting Edge
UPC-RT
UPC-RR
Cutting Edge
R
R
0.5
Rake Face
Flank
W+0.5
Corner Radius: 5 μm
Micro cracks
(1) L: 51, W: 6.35 (2) L: 60, W: 8 Standard Size 60°
Nanometre-level ne machining is possible D Sharp Cutting Edge Machining without deforming or damaging workpieces during ne nishing D Cutting Edge Without Chipping Mirror surface without transfer of workpiece irregularities Mirror nishing of Ra 5nm or less is possible UPC cutting edge Cutting edge with microscopic irregularities
Dimensions and Highest Accuracy
Width of Cut W (RR)
Cutting Edge Angle
Relief Angle
Edge Waviness (μm)
Corner Radius R
Rake Angle
Cat. No.
≤90°
≤120°
≤150°
Very High Precision High Precision
0.05
0.1
0.20 0.002 to 200
0.5 to 5
0° to 20° -30° to 10°
20° or more
UPC-R
0.25
0.5
1
*Please consult us as dimensions and accuracy vary depending on the combination of each element.
Ultra-precision Cutting Tool UPC-R For Various Mold Machining (Infrared Lens Molds, etc.)
Makes its presence felt in ne machining of hard brittle material Tool life was a problem when machining germanium and silicon lenses used in infrared sensors and night-vision lenses. Proprietary ne edge treatment applied to a single-crystal diamond cutting edge has enabled signi cant extension of tool life.
Features D Cutting edge height (centre height) is the same on any conical surface. D Sharp cutting edge with nanometric precision. D Cutting edge can achieve 0.05μm waviness precision. D Also applicable to machining of calcium uoride or cemented carbide. Applications D Infrared sensor lenses, night-vision camera lenses, germanium lenses, silicon lenses, calcium uoride lenses, cobalt-free carbide molds
Comparative Examples 1) Work Material
: Infrared sensor transmissive lens, ø95mm germanium
2) Tool Speci cation 3) Cutting Conditions
: Corner radius 1.5mm, relief angle 10°
: Rotation speed 2,000min -1 , feed rate 1.75μm/rev, allowance 1.5μm
UPC Cutting Edge for Infrared (IR) Lenses and Cemented Carbide Molds
Results
250
2.4x tool life
200
150
1 to 3μm
100
Negative Rake Face
50
Flank
0
For Infrared Lens
Conventional Tool
*Conventional Tool as 100
Uniform Negative Rake Face of Cutting Edge
AL10
For Optical Shim Mold Machining, etc. For Micro Lens Array Mold Machining, etc. Ultra-Precision Cutting Tool UPC-Nano Groove / UPC-Nano Ball Endmill Optical Components
Ultra-precision Cutting Tool UPC-Nano Groove For Optical Shim Mold Machining, etc.
Enables high-precision linear grooving with a cutting edge width among the world's smallest. Grooving holder with 5μm minimum groove width. Enables quick high-aspect-ratio machining that cannot be achieved using the photolithography method or ion-beam method. The high-precision, durable cutting edge is the ideal tool for ne, clear grooving of hologram diffraction gratings, linear ne grooving, LCD light guide plates, and so on.
Features D Grooving holder with 5μm minimum groove width. D Durable cutting edge with high-precision grinding. D Enables high-precision ne grooving that cannot be achieved using the photolithography method or ion-beam method.
AL
Applications D For linear ne grooving, optical shim molds, light guide plate mold machining
Cutting Edge Shape
L
X
45°
45°
A
Cutting Edge Shape
Nano Groove Cutting Edge
(1) L: 51, W: 6.35 (2) L: 60, W: 8 Standard Size
Ultra-precision Cutting Tool UPC-Nano Ball Endmill For Micro Lens Array Mold Machining, etc.
World's smallest ballnose endmill Enables high-precision 3D machining with its extremely sharp cutting edge. Fine 3D curved surfaces can also be machined, as well as quick machining of multiple ne spherical holes.
Features D This ballnose endmill is the world's smallest in its class with a radius of 30μm. D World's highest class prole of 50nm is also possible. D Enables high-precision 3D machining with its extremely sharp cutting edge.
Applications D For micro lens array molds, LCD light guide plate molds, ne machining molds
Cutting Edge Shape
L
0 to 0.005
30°
R
Window Angle
45°
100μm Example of Cutting Using a Nano Ballnose Endmill
10μm
(0.010)
Cutting Edge Shape
G
5
20°
20
(1) L: 50, W: ø6 (2) L: 40, W: ø4
Standard Size
AL11
For LCD Light Guide Plate Mold Machining, etc. For Optical Shim Mold Machining, etc. Ultra-Precision Cutting Tool UPC-Nano Endmill / UPC-Nano Profile Optical Components
Ultra-precision Cutting Tool UPC-Nano Endmill For LCD Light Guide Plate Mold Machining, etc.
Enables world's smallest class of free-form ne grooving This endmill enables machining of rectangular grooves along free curves. Enables quick high-aspect-ratio machining in edged shapes that cannot be achieved using the photolithography method or ion-beam method. Features D Enables machining with a high aspect ratio 2.5 times the rotation diameter. D Durable cutting edge with high-precision grinding. D Enables high-precision ne grooving that cannot be achieved using the photolithography method or ion-beam method.
AL
Applications D For machining of LCD light guide plate molds, hologram diffraction grating molds, free-form ne grooving
Cutting Edge Shape
L
45°
B
(0.5)
500μm Example of Cutting Using a Nano Endmill
Cutting Edge Shape
G
5
16
(1) L: 50, W: ø6 (2) L: 40, W: ø4
Standard Size
Ultra-precision Cutting Tool UPC-Nano Profile For Optical Shim Mold Machining, etc. Formed Single Crystal Diamond Tool with Free-form Cutting Edge When machining multiple formed grooves or over a long distance, a formed tool makes it easy. UPC-Nano Pro le is an ultra- ne formed cutting tool with a free-form pro le on its single crystal diamond cutting edge.
Features D Enables exible one-pass machining of free-form surfaces including elliptical and paraboloidal surfaces with a pro le accuracy of 1μm or less. D Ensures high-pro le accuracy in machining of paraboloidal and other free-form surfaces. Applications D For optical lens molds, liquid crystal panel optical shim molds, micro lens array molds
Ellipse
0.05mm
Concave Round Cutting Edge Shape
Oval Cutting Edge Shape
AL12
For Glasses Lens Roughing For Glasses Lens Finishing PCD Face Milling Cutters / New D Holders
Optical Components
PCD Face Milling Cutters For Glasses Lens Roughing
Ef ciency is improved not only for face milling but also free-form pro le milling and grooving. Tool speci cations can be manufactured to order with requirements like mono-block tool bodies and indexable cutting edges.
Features D Improves machined surface roughness and suppresses burrs. D Proprietary tool design balances reduced machining time and tool life. Applications D Glasses lens roughing, resin molded parts, aluminum die cast alloys and other non-ferrous metal components
AL
New D Holders For Glasses Lens Finishing
The sharp cutting edge achieves the high shape precision and mirror finish required for glasses lens finishing.
Features D The combination of our uniquely designed inserts and holders enables easy and precise tool setting, as with indexable inserts. D The rake face is free from adhesion and accumulation of chips, maintaining a high quality in worked surfaces even during continuous use.
Applications D For Glasses Lens Finishing D For Resin Part Machining
Comparative Examples (Glasses Lens Machining Examples)
[Results] Shape Precision: 0.8μm Surface Roughness (Ra): 0.1μm Output:
R2.0 Relief Angle 18° 1,200m/min 0.25mm/rev 0.08mm
1) Tool Specification 2) Cutting Speed 3) Feed Rate 4) Depth of Cut
2,000 pcs
Glasses Lens
Microscope Photo of Machined Surface
AL13
MEMO
AL14
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