Polycrystalline diamond (PCD) and cubic boron nitride (CBN) inserts are advanced cutting tools that offer unique material properties, making them popular in machining processes. Here are the key features and applications of PCD and CBN inserts:

• Material Hardness: PCD inserts exceed the hardness of traditional carbide tools, making them ideal for cutting non-ferrous materials.
• Wear Resistance: PCD's hardness contributes to excellent wear resistance, making it suitable for prolonged tasks with minimal tool degradation.
• Thermal Conductivity: PCD has excellent thermal conductivity, aiding in heat dissipation during machining, helping tool integrity and reducing the risk of thermal damage.
• Surface Finish: PCD tools provide superior surface finish and dimensional accuracy, necessary for high-precision applications.
• Chemical Stability: PCD is resistant to chemical reactions, making it suitable for machining materials that may be reactive or abrasive.
• Low Friction: The low friction coefficient of PCD reduces the cutting forces needed, allowing for high-speed machining.
• Versatility: PCD inserts can be used for various operations, including turning, milling, and drilling, primarily on non-ferrous materials such as aluminum, composites, and plastics.

• High Hardness: CBN is the second hardest material after diamond, making CBN inserts suitable for cutting hard ferrous materials, including hardened steels.
• Wear Resistance: CBN exhibits excellent wear resistance, especially in high-speed machining environments.
• Thermal Stability: CBN can withstand high temperatures without significant degradation, an advantage for cutting applications generating high heat.
• Chemical Stability: CBN is chemically stable at high temperatures, crucial when machining materials that may generate reactive conditions.
• Edge Strength: CBN inserts maintain edge integrity better than traditional carbide tools when cutting hard materials, reducing the risk of chipping or breaking.
• Cutting Efficiency: CBN tools allow for efficient chip removal and reduction in machining forces, which may enhance productivity.

PCD inserts are ideal for non-ferrous materials, while CBN inserts are better suited for hardened steels and iron-based materials, making them a common choice in automotive and aerospace applications.

PCD is more expensive due to the diamond content and manufacturing process, while CBN is somewhat less costly. Additionally, both inserts offer prolonged tool life compared to conventional carbide due to their hardness and wear resistance.

PCD and CBN inserts are essential components in the modern machining industry. Understanding the specific features and benefits of each type can help manufacturers select the right inserts for their machining needs, leading to greater efficiency and superior performance.

The technical parameters of PCD (Polycrystalline Diamond) and CBN (Cubic Boron Nitride) inserts can vary based on their specific application, geometry, coating, and manufacturer. However, some common technical parameters are often evaluated when considering these inserts. Here’s an overview of typically relevant parameters for both PCD and CBN inserts:

• Material Composition: PCD inserts are made from diamond particles bonded with a metal matrix, which may vary depending on the specific application.
• Hardness: Vickers Hardness: Typically > 6000 HV, depending on the composition and manufacturing process.
• Thickness: Common Thickness: Ranges from 0.5 mm to 10 mm, depending on the application.
• Grain Size: Average grain size: Can vary from 1 μm to several microns, influencing wear resistance and toughness.
• Thermal Conductivity: Thermal Conductivity: Around 700-900 W/m·K, making it effective for heat dissipation.
• Coating: Common coatings: PVD or CVD coatings may be applied to enhance performance, depending on the material being machined.
• Edge Preparation: Geometry: Sharpened or honed edges can enhance cutting performance in specific applications.
• Geometry: Insert shape: Various shapes available such as round, square, triangular, and more, each optimized for particular cutting applications.
• Chip Breaker Design: Available designs: Various chip breaker configurations can enhance chip control and improve cutting efficiency.

• Material Composition: CBN inserts are typically made of cubic boron nitride in a solid form, sometimes in combination with a binders such as cobalt or ceramic.
• Hardness: Vickers Hardness: Typically 4500 - 5000 HV, providing excellent wear resistance for hard materials.
• Thickness: Common Thickness: Similar to PCD inserts, ranges from approximately 0.5 mm to 8 mm or more based on specific applications.
• Thermal Stability: Operating Temperature: CBN can withstand temperatures up to about 1000°C (1832°F) without significant degradation.
• Coating: Common coatings: Often includes TiN, TiC, or Al2O3 coatings, which can enhance wear resistance depending on the application.
• Edge Preparation: Geometry: Suitable edge preparations to optimize performance based on the specific material and machining operation.
• Geometry: Insert shape: Various shapes are also available like square, round, and octagonal, facilitating different types of machining operations.
• Chip Breaker Design: Available designs: Various chip breaker geometries are used for controlling chip flow and optimizing cutting conditions.
• Grain Size: Average grain size: Typically varies according to the manufacturing process and intended use; finer grain sizes offer better edge stability.

• Insert Size: Standard insert sizes follow the ISO metric system (e.g., ISO ISO 8885:1993) and ANSI standard (e.g., ANSI B212).
• Flank Wear Resistance: Measurement of flank wear resistance is critical for assessing tool life. This is sometimes measured in microns (µm) after standard machining tests.
• Cutting Edge Strength: The cutting edge strength is essential for evaluating performance under different cutting conditions and materials.
• Application Information: Each insert is often designed for specific cutting operations (turning, milling, etc.) and materials (aluminum, hardened steel, etc.).

PCD inserts and CBN inserts both hold significant importance in numerous industrial applications. These cutting tools are designed to cater to specific materials and machining conditions that are unique to the manufacturing process. Having a clear understanding of the distinguishing features of these tools helps manufacturers to fine-tune their processes and produce high-quality outcomes more efficiently.

It is essential for users to carefully determine which insert is best suited for the job at hand based on various factors such as the material being worked on, the required tolerance levels, and the desired surface finish. This will result in selecting the ideal insert, leading to enhanced productivity, better process optimization, and quality results.