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* Make sure that the machine has adequate rigidity, and use rigid tool holders and fixtures to minimize chatter and vibration. This will help promote longer life and better surface finishes.
* When "PCD" blank tools replace conventional diamond tools or cemented tungsten carbide, start with the same tool geometries except where other tool geometries have been proven. As experience is gained, it may be possible to refine the "PCD" blank tool's geometry for even better tool performance.
* When replacing conventional diamond tools with "PCD" blank tools, increase the rake angles and use the same machining conditions. Increase depth of cut (D.O.D.) and feed to improve productivity.
* When replacing cemented tungsten carbide tools with "PCD" blank tools, increase speeds by at least a factor of three (3) where possible, to increase productivity. Use of a somewhat greater depth of cut will also improve productivity.
CUTTING FLUIDS
* "PCD" blank tools can be used to machine parts either wet or dry. In most cases, however, tool performance is improved by use of a cutting fluid. Soluble oil/water emulsions similar to those used when machining with cemented tungsten carbide tools are widely used, with excellent results. Their lubricating qualities help to reduce frictional heating and the formation of build-up edges while promoting good chip flow.
* Whenever possible, machine wet with "PCD" blank tools. Standard soluble oils give excellent results. While satisfactory results can be obtained when machining dry, cutting fluids help to improve tool life and workpiece finishes in many cases. Cutting fluids also help to wash chips away from the tool/workpiece interface and reduce the tendency to develop a build-up edge.
* Establish a criterion for tool life and change tools as soon as that point is reached. Do not continue to run "PCD" blank tools after they have lost their sharp edge.
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