Applications guide

Where diamond tools work, which group suits which material, and where to start with cutting data. Treat the values as starting points and follow the manufacturer's recommendation for the grade you order.

Tool choice by workpiece material

Workpiece material First choice Second choice Note

Aluminium, up to 12% SiPCD, medium or fine grainCVD-coated carbideHigh speed, plenty of emulsion.

Aluminium, 12 to 17% SiPCD, medium to coarse grainTFDSilicon particles wear the edge faster.

Aluminium, above 17% SiPCD, coarse grainTFDTool life is the deciding factor.

Copper, brass, bronzePCD, fine grainSingle-crystal for optical workUse a sharp edge.

Metal matrix compositePCD, coarse grainTFDLower speed than plain aluminium.

CFRP and GFRPPCD, coarse grainCVD-coated carbide or TFDFibre dust: extraction and filtration needed.

GraphiteCVD-coated carbidePCDGraphite dust: extraction needed.

Green ceramic or carbideCVD-coated carbidePCDDry cut or oil mist.

Plastic, engineered woodPCDCVD-coated carbideMDF and chipboard are highly abrasive.

Optics: Al, NiP, Ge, Si, ZnSeSingle-crystal diamondNoneUltra-precision machine with air bearings.

Steel, cast iron, nickel alloysNot diamondPCBN, carbide, ceramicDiamond reacts with iron and nickel above about 700 °C.

Starting cutting data

Typical starting ranges for PCD and CVD tools. Adjust to your machine, rigidity and surface requirement.

Material Speed, m/min Feed, mm/rev Depth of cut, mm

Aluminium, low Si500 to 20000.05 to 0.30.1 to 4

Aluminium, 12 to 17% Si300 to 8000.05 to 0.250.1 to 3

Aluminium, above 17% Si250 to 6000.05 to 0.20.1 to 2

Copper and brass200 to 6000.05 to 0.20.1 to 2

Metal matrix composite100 to 4000.05 to 0.20.1 to 2

CFRP and GFRP100 to 4000.05 to 0.250.2 to 3

Graphite200 to 6000.05 to 0.20.1 to 2

Optics (single-crystal)Set by the machine. Feed 1 to 10 µm/rev, depth of cut 1 to 20 µm.

Typical industries

Automotive

Aluminium wheels, pistons, cylinder blocks and heads, gearbox housings, brake components.

Aerospace

CFRP and GFRP tubes and shells, aluminium structural parts.

Electronics and electrical

Heat sinks, aluminium housings, copper contacts and commutators, bearings in bronze.

Tooling and energy

Graphite EDM electrodes, fuel-cell bipolar plates, green ceramic and carbide preforms.

Optics

Metal mirrors, infrared lenses, NiP-plated moulds, polymer lenses, hard-disc substrates.

Wood and plastics

MDF, chipboard, laminates and filled plastics.

Good practice

Keep the set-up rigid and the run-out low. Avoid interrupted cuts with TFD and single-crystal tools. Use plenty of emulsion in aluminium to stop chip welding. Replace the edge when roughness, burrs or cutting force rise.

Graphite dust and carbon fibre dust are a respiratory and electrical hazard. Use extraction and filtration.

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