Something old, something new….

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old carbide tipped cutter versus precision carbide insert cutter

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old carbide tipped raised panel cutter versus precision carbide insert cutter

We’ve come a long way in the arena of cutting tool design…but it is always surprising to see unbalanced, outdated and poorly designed cutting tools in operation on production equipment. Using a carbide-tipped cutter in a production setting is neither cost-effective, dependable, nor does it provide the quality and repeatability that customers demand. Here are two examples which recently enabled us to introduce and upgrade customers into 21st century cutting tool standards. The new insert tools will guarantee a quiet-running, balanced tool that provides a longer run time, quick tool changes, 100% pattern repeatability/constant diameter and lower tooling cost over time. Which one do you want on your shop floor?

for more info visit us at www.guhdo.com/video or call 800-544-8436

Getting Deep on Diamond Tooling

Diamond is known as a material with impressive characteristics. Even the name, Diamond, which stems from the ancient Greek word  “αδάμας” – “adámas,” translates to unbreakable. In particular diamond is the hardest mineral known and also has the highest thermal conductivity. These two traits, in addition to its abrasion-resistance,  make Diamond quite a popular material in the industrial tooling area. To illustrate the level to which diamond tools surpass carbide tools in regard to hardness, one only has to compare each materials value on the Knoop hardness scale. While synthetic diamond generally rates between 5000 to 7000, the average hardness for a carbide tool only has a value of about 1700 to 2400.

Hardness Scale

Hardness Scale

Polycrystalline Diamond tools are an established, well accepted solution for high volume production and they are now cost effective as well. They have long proven to be an investment in quality AND productivity as they can provide substantial savings in tooling costs.

Diamond Router Bit

Diamond Router Bit

Based on case histories, polycrystalline diamond tools can outlast a carbide tool by a ratio of roughly 300:1. However, this takes into account a wide range of materials machined.   So, while one machinist may achieve a ratio of 50-fold life span for a diamond tool cutting very abrasive material, another may outrun his previously used carbide tool by 800 times on a solid wood application.

A sampling of styles available to machine a wide range of materials such as MDF, particle board, solid surface material, phenolic etc.

A sampling of styles available to machine a wide range of materials such as MDF, particle board, solid surface material, phenolic etc.

Today, diamond tools have earned their position in most every woodworking, composite, plastic and solid surface cutting application.  From routing and edge-banding, profiling, sawing, jointing and grooving to slotting and hogging; diamond tools are used in almost all cutting tool applications.

Today’s modern manufacturing facilities  are running expensive CNC machining centers with constant demand for higher output and lower unit costs being paramount.  Most CNC machinists have recognized the value of diamond cutting tools. Elimination of downtime alone can result in a significant reduction in tooling costs, not even taking reduced sharpening costs, stocking needs and lost production into consideration.

Although diamond tools may not be the solution to every tooling issue, they should not be excluded from consideration without a thorough analysis of the potential advantages. With today’s ever-increasing demand for higher efficiency and lower costs, the toughest material may just solve the toughest tooling problems!

HSK 63 F Tool Holders for CNC Machines

HSK 63 F Tool Holders for CNC Machines

Diamond vs. Carbide Tooling Cost Comparison

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Diamond Router Bits

It is well-known that Polycrystalline Diamond (PCD) tooling delivers high performances in cutting applications while also significantly while reducing a company’s overall tooling costs.  Under the right conditions and with the proper maintenance, great cost savings can be achieved. The first tool life can yield savings of up to 30 -50% in comparison to carbide tools or inserts. And subsequent sharpenings will further increase the savings when compared to a carbide tool or insert.

Solid Carbide Compression Router Bit in HSK 63 F Tool Holder

Solid Carbide Compression Router Bit in HSK 63 F Tool Holder

To illustrate the cost savings we have created the example cost comparison below:

The Formula: 

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The Data:

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The Example Cost Comparison (per Linear Foot Machined):

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The calculation quite accurately illustrates, that although at first look Diamond tools seem to be a costly investment, it is an investment that pays off rather quickly and costs only a fifth of what equivalent Carbide tools would cost.

It may not be necessary to buy Diamond Tools for everyone and every company, but especially those who need their tools to last as long as possible and would like to get as much use out of them as possible, will find that investing in diamond tools is more than cost-effective.  The best applications for diamond tools are those machining  abrasive materials and doing high volume of the same cut. We are now offering select tooling online.