Becker PCD diamond inserts with chipbreakers - followup

Salesman came in with his diamond specialist (from Tyson Tool in Weston - Toronto, ON).
I wrote a test program so we could fiddle with speeds, feeds and DOC
to get the breaker working. Virtually unnecessary.
1st successful cut actually broke chips(!) in our 6061 aluminum bore. Very simiar to the video indeed.(
http://www.youtube.com/watch
? v=8pgc8ArXiRc& - use must use coolant, despite video)
While fiddling with the DOC and feed does yeild better chip control, I'd say the insert is still quite tolerant of different conditions. You just have to follow their (generous) guidelines.
Very impressed. Best $90 we've ever spent.
Insert is DCGT 3252 CB1 (that's the fine chipbreaker) .005-.040 radDOC, 0.004(fin)-0.007(rough) feedrate. We are using a sold carbide bar with 3/4" shank from Tungaloy as the bore is about 5:1 (1.09" diameter)
We also picked up a CCGT 2151 CB1 for another difficult boring operation. Can't wait to try it.
Cycle time on the part was 3:30 before. Now it's 2:35 without any optimization for the diamond insert (may work on that later today). Cycle time is shorter because of NO retracts to clear nests, NO chip pulling cycle (custom hook doo-dad). Under an 80X mircoscope you can see each revolution, clean and no chip welding.
Chips are small (as per video) and very dense. The recycler might stop complaining about our light drums.
HIGHLY RECOMMENDED!
Regards.
Robin
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Robin S. wrote:

Robin, Thanks for the follow up
Best, Steve
--


Regards,
Steve Saling
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wrote:

Interesting.
How will PCD work in brass? I'm thinking swiss machine made rifle bullets - the shinier the better.
--

-JN-

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On Tue, 23 Mar 2010 07:19:58 -0700 (PDT), "Robin S."

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