PCD (Polycrystalline Diamond) is a composite superhard material sintered from diamond micropowder and cobalt binder under high temperature and ultrahigh pressure (1400-1600℃, 5-7 GPa). It inherits the key advantages of diamond, including extremely high hardness, outstanding wear resistance, high elastic modulus, isotropy, and relatively high thermal conductivity.
PCD cutting tools are typically produced by brazing PCD compact inserts onto carbide or steel tool bodies. This composite structure combines the high hardness, wear resistance, and low friction coefficient of diamond with the high bending strength of tungsten carbide. The carbide layer provides strong mechanical support for the diamond layer, greatly enhancing the tool’s bending resistance.
1.Misconceptions and Challenges in 3C Manufacturing
In the 3C industry, the primary materials being machined are plastics and aluminum. Many people assume these materials are easy to machine, but this is a significant misconception. Modern 3C products make extensive use of fiber-reinforced plastics. When machining these materials with conventional carbide tools, achieving good surface quality typically results in a tool life of only about 100 workpieces.
Furthermore, the product designs in the 3C sector are becoming increasingly complex, with widespread use of non-standard and irregular contours. This places extremely high demands on tool consistency. Ensuring consistent performance with carbide tools on such complex geometries is far more difficult than with standard end mills.
As a result, unless the surface-quality requirements of appearance parts are reduced, it is difficult for carbide tools to break through this tool-life limitation—because the constraint is fundamentally dictated by the material properties of the tools themselves.
2.Unique Advantages of PCD Tools in 3C Product Manufacturing
In contrast, PCD tools offer extremely high wear resistance, a low friction coefficient, and ensure exceptional consistency of machined products. When manufactured with precision, their service life can easily exceed 1,000 workpieces—a performance that cemented carbide tools can never match. In the 3C industry, where product surface quality is crucial, PCD tools provide ultra-long service life and stable machining performance, helping companies reduce costs while guaranteeing high-quality output.
3.Key Factors in PCD Tool Manufacturing
One of the key technologies in PCD cutting tool manufacturing is improving the grinding quality of the cutting edge. Even with high-quality PCD tip materials, the lack of proper grinding processes and technology can lead to significant material waste.
By adopting advanced grinding processes and using appropriate grinding wheels, manufacturers can effectively enhance tool quality while reducing both production and application costs. This not only determines the tool’s cutting performance but also directly influences cost control and productivity for the enterprise.
4.Choose SNSTC — Professional Solutions for Your Machining Needs
With over 30 years of dedication to cutting-tool technology, SNSTC has developed deep expertise in PCD edge-grinding processes. We understand the critical role PCD tools play in 3C manufacturing and excel at resolving all major technical challenges across both rough and fine edge grinding. For applications requiring complex tool geometries or demanding extreme tool life and machining quality, we deliver fully customized, end-to-end technical solutions.
We are committed to using our expertise and experience to support your 3C manufacturing. Choosing SNSTC means choosing efficiency, stability, and excellence. Contact us to unlock a new chapter in 3C machining—let PCD tools empower your business growth!
