About Us

PCBN  Compact Tools

A complete line of high quality poly-crystalline CBN products for machining ferrous materials. These products are surnished in different shapes, sizes and grades for fabrication into finished tools.

Engineered for Superior Performance

PCBN Compacts consist of fine particles of CBN integrally bonded with a . cemented tungsten carbide substrate or produced as solid PCBN products. The CBN crystals are randomly oriented and strongly bonded to each other, or to a ceramic matrix material, providing uniform high hardness and wear resistance in all directions. The carbide substrate provides excellent mechanical support so the PCBN abrasive layer for severe interrupted machining applications.

The solid PCBN products consist of micron sized CBN crystals and ceramic phases sintered together, resulting in a cutting tool material with high fracture resistance, wear resistance and thermal, as well as chemical, stability. PCBN Compacts resist chemical reaction with iron and are specifically designed for machining different types of ferrous materials. In automotive, aerospace and heavy industry PCBN Compacts excel on cast irons, hardened steel, powder metal, hard facing alloys and superalloys.

The Most Cost Effective Tooling   

In a typical machining application, tool cost is a small percentage- of the total production cost. The full potential and value of PCBN Compact tools over competitive and conventional tooling is evident by gains in productivity and cost savings in  the total manufacturing operation.


PCBN Compacts Deliver

• Higher material removal rates 10 decrease cycle times providing more parts per shift
• Faster cutting speed capabilities relative to conventional materials
• Improved workpiece quality, excellent dimensional control, consistent surface finishes, reduced scrap.
• Longer tool life resulting in increased machine up-time, providing greater production capacity without investing in new equipment.

Application:

·          Hard Cast Iron

·          Pumps

·          Impellers

·          Shafts

·          Rolls

Soft Cast Iron:

·          Engine Blocks

·          Brake Rotors

·          Brake Drums

·          Clutch Plates

·          Transfer Housings

Sintered Iron:

·          Valve Seats

·          Cam Shafts

·          Gears

Hardened Steel:

·          Pinion Gears

·          Side Gears

·          Transmission

·          Shafts

·          Bearings

Superalloys:

·          Turbine Disk

·          Turbine Blade

·          Turbine

·          Shrouds

·          Engine Shafts

·          Turbine Vanes

With the proper use of qualitative raw material such as micro grain solid carbide products and others we manufacture a wide range of hand and machine tools.

Our range includes ball nose and end mill cutter, drill-reamers-step drills-step reamers-central drills, slitting saw - side and face cutter, form cutters, punches, t-slot, do-tail cutters,  engraving tools and taper cutters, tailor made cutters and any types non standared products.

Woodworking End User Benefits:

• Increased Production Rates; 3-5X Carbide
• Improved Workpiece Quality; Dimensional Control, Surface Finish
• Longer Tool Life; 100-500X Carbide
• Increased Machine Tool Uptime; 10-20% Average
• Machine Capacity Growth Without Investment
• Lower Tool Cost Per Unit or Product
  

Lower Energy Requirement:


WHY PCD TOOLS FOR WOODWORKING?

As many of you know, the timber industry has experienced many drastic changes over the past few decades. Land management cutting policies enforced on forest product companies combined with higher costs and governmental/environmental constraints have severely restricted the availability of many natural wood materials. This has led to the rapid growth of the various composite board types which are being used extensively throughout the construction and furniture industry. White more economical to use. composite materials present unusual difficulties in forming and cutting operations because of their inherent abrasive components.

Particleboard, medium density fiberboard and composite materials, including ply-wood and other laminates Like melamine and high pressure plastics, present very harsh conditions for today's conventional tooling. In the case of particleboard, the varying layers of density from surface to surface create uneven tool wear across the length of the cutting edge when conventional tool material is used. This will result in chipping or burning ai the surface interface and particle tear out of the core material.

Tool life is one of the most important factors to manufacturers producing wood products. Short tool life not only reduces productivity of an operation but also introduces wide variations in machined surface quality and dimensional tolerances - which can create major problems for subsequent operations. The cutting edge of a PCD tool wears very slowly by the microfracturing of the small individual crystals in the polycrystalline layer. Because the crystals are uniform in size and hardness, and evenly distributed throughout the diamond layer, wear tends to be slow and even. This is what gives diamond tooling its remarkable advantage over conventional tool materials.

Polycrystalline Diamond (PCD) is a synthetic diamond product that is produced by sintering together selected diamond particles with a metal matrix using sophisticated technology. The diamond and matrix, when sintered together under high temperatures and pressures, creates a  PCD tool blank that is high in uniform hardness and is abrasive resistant in all directions. This PCD diamond layer is then bonded to a tungsten carbide substrate, which provides strength and a brazable base to permit bonding to other metals.

Polycrystalline tipped tools are exceptionally resistant to wear compared to tungsten carbide or ceramic tools. In certain applications, PCD tool life can exceed carbide
cutting tool life by 50 to 1 00 times. PCD is more shock resistant over natural diamond because of its random orientation structure of the diamond particles, and is bocked by a carbide substrate. In certain applications, polycrystalline tipped tools have several advantages over natural diamond.

PCD is more constant in wear. Again because of the random orientation of diamond particles. Natural diamond is a single crystal in nature and has soft and hard grains. Depending on the shape of the natural diamonds the tool being manufactured, it is sometimes not practical to have hardest grain on the cutting edge.

PCD costs are considerably lower than the cost of natural diamond stones, and the availability of different shape PCD blanks reduce manufacturing cost significantly. The longer of a cutting edge required, the larger the savings of  PCD over natural diamond due to the rarity of larger stones.

Polycrystalline diamond tooling can be used in a wide range of rough, finish and super finish machining operations such as milling, grooving, turning, facing, drilling and boring, recommended for non ferrous metals and abrasive non metallics.

MATERIALS RECOMMENDED FOR CUTTING WITH  PCD:

Aluminum and aluminum alloys , Copper, brass and bronze alloys, Zinc and magnesium alloys, Gold and silver, Tungsten carbide, presintered and sintered, Carbon and graphite, Ceramics, unfired Epoxy resins, Plastics and rubber, Fiberglass composites, Graphite composites, Phenolic, Chipboard and fibreboards. PCD cutting tools are available in various grades, depending on the application.

With a long experience for more than 23 years, we are engaged in manufacturing a vast array of cutting tools. We possess modern manufacturing and testing facility which enables us to produce our range without any flaw and defect. In addition we maintain a healthy relation with our client and make necessary improvements as per their valuable suggestions. Some of the important facts that made us favorite of our clients:         

•     Superior quality products
•     Timely delivery
•     Large distribution network
•     Customized solution
•     Ethical business practices
•     Competitive prices