PCD Inserts (Polycrystalline Diamond Cutting Tools)
UKing Diamond’s factory-direct full-face PCD inserts deliver 50×–100× longer tool life, superior wear resistance, and mirror-like surface finishes (Ra ≤ 0.2 μm), making them ideal for high-speed machining of aluminum alloys, CFRP composites, copper, and other abrasive non-ferrous materials.
Request a Quote
Enter the quantity you need and add to your quote list for pricing inquiries.
Description
Uking Diamond Full-Face PCD Cutting Inserts
Uking Diamond’s full-face PCD cutting inserts eliminate the fragile brazed joints common in tipped tools, providing maximum structural rigidity across aggressive cutting parameters. Our optimized diamond micro-grain grades are structurally tuned for high-speed, continuous, and interrupted operations in specific modern materials:
- Aerospace Carbon Fiber (CFRP/GFRP) & Epoxy Composites
Delivers clean, fiber-shear mechanics that completely eliminate delamination, fiber pull-out, and localized burring during high-feed nesting and routing. - Automotive High-Silicon Aluminum Alloys (Al-Si Alloys)
Successfully resists the intense abrasion of hard silicon particles (e.g., A390 casting formulas) without crater wear or edge grounding, maintaining strict geometric stability. - Copper Alloys, Brass & Precious Metals
Inherently thwarts built-up edge (BUE) formation thanks to the natural low friction coefficient of pure diamond, ensuring exceptional chip flow and continuous mirror-like finishes ( Ra≤0.2 μm ). - Abrasive Geotechnical Ceramics, Graphite & Wood
Prevents premature abrasive edge wear in dense graphite electrodes, bisque ceramics, and hard engineered boards (MDF/HDF), outlasting conventional carbide by up to 100×.
| ISO Standard Model | Insert Geometric Configuration | Primary Mechanical Application | Industry Standard Sizes |
| CCGW Series | 80° Rhombic (Diamond profile) | [Precision Finishing] High-precision turning & profiling of aluminum bars and aerospace CFRP components. Optimized for continuous finishing passes. | CCGW 060204, CCGW 09T304… |
| DCGW Series | 55° Rhombic (Narrow diamond) | [Complex Profiling & Narrow Clearance] Intricate copying, complex profiling, and back-turning inside narrow clearance profiles. Minimizes lateral vibration stress. | DCGW 070204, DCGW 11T304… |
| TCGW Series | 60° Triangle (High versatility) | [General Turning & Multi-Edge Economy] General turning, high-feed facing, and shoulder clearing. Delivers multi-edge operational economy. | TCGW 090204, TCGW 110204… |
| WCGW Series | 80° Trigon (Aggressive edge) | [Medium Roughing & Interrupted Cutting] Medium roughing and heavily interrupted cuts in volatile castings. Offers maximum tip fracture toughness. | WCGW 060204, WCGW 080404 |
| SCGW Series | 90° Square (Maximum rigidity) | [Heavy-Duty Face Milling & Slotting] Heavy-duty face milling, slotting, and shoulder milling cutter blocks. Engineered for ultimate edge strength. | SCGW 09T304, SCGW 120408… |
Product Details
1. The Engineering Superiority of Full-Face Solid Construction
Traditional tipped PCD inserts rely on vacuum brazing to glue a tiny diamond segment onto a carbide base. Under high-speed machining temperatures (~800°C) and severe structural vibrations, these brazed seams are notorious for thermal stress fatigue, causing sudden tip delamination and expensive workpiece scrap.
Uking’s Full-Face PCD inserts completely eliminate this structural vulnerability. The entire top layer of the insert is a single, continuous ultra-high-pressure high-temperature (HPHT) sintered polycrystalline diamond grid. With no brazing seams to fail, you can double your cutting speeds ( Vc ) and feeds ( fz ) with absolute process predictability.
2. Advanced Multi-Grade Sintering & Custom Edge Preparation
We do not believe in a single-grade tool solution. Our manufacturing plant operates multi-modal grain matrix blending:
- Sub-micron Fine Grades: Tailored for absolute sharpness, creating pristine edges for mirror-finishing aluminum and zero-defect optics.
- Coarse/Medium Co-Sintered Grades: Engineered with higher cobalt-mesh cross-linking for excellent fracture toughness, absorbing severe cyclic impacts during interrupted roughing.
Furthermore, each batch undergoes customized edge preparation—ranging from atomically sharp edges to calibrated hones or custom T-lands (chamfers)—perfectly matched to your specific workpiece hardness and machine tool rigidity.
PCD vs. Carbide Inserts — Quick Comparison
| Property | PCD Insert | Carbide Insert (K10) |
| Hardness (HV) | > 8,000 HV | ~1,500–1,800 HV |
| Thermal Conductivity | 540–560 W/m·K | ~80 W/m·K |
| Tool Life (Al machining) | 50–100× longer | Baseline |
| Surface Finish (Ra) | ≤ 0.2 μm achievable | ~0.8 μm typical |
| Best For | Non-ferrous, composites, abrasives | Steel, cast iron, general-purpose |
Developed in the 1970s and now standard across aerospace, automotive, electronics, and stone fabrication, PCD inserts remain the highest-productivity solution for non-ferrous machining — combining diamond hardness with practical tooling economics.
Why Choose Uking Diamond PCD Inserts?
Elimination of Brazed Tip Failures: Solid full-face integration ensures 100% mechanical consistency, preventing severe tooling disintegration under deep cuts.
Multiple Fresh Usable Cutting Edges: Maximizes your tooling ROI by providing multiple usable corners per insert, lowering your total cost-per-part drastically.
Predictable Mirror Surface Finish: Achieves and stabilizes a surface roughness of Ra ≤ 0.2 μm throughout extended production campaigns without manual indexing intervention.
Perfect Drop-In ISO Compliance: Fully engineered to international standards, fitting seamlessly into your existing CCGW, DCGW, and TCGW boring bars and face milling heads.
Application
Ready to Multiply Your Tool Lifespan?
Are your CNC machining lines suffering from frequent downtime, sub-optimal surface finishes, or severe tip brazing failures in high-silicon aluminum or abrasive composites?
Stop draining your production margins on outdated tipped inserts that fail under aggressive modern machining feeds. Backed by 20 years of ultra-high pressure metallurgical engineering expertise in Henan, China, Uking Diamond manufactures industrial-grade Full-Face solid PCD cutting inserts that keep your spindle turning and your scrap rates at zero.
Note: Because high-grade full-face PCD inserts are precision-engineered production assets rather than cheap consumer commodities, we do not distribute unchecked free samples. We protect our technical integrity and focus on real engineering alignment.
Unlock Your Corporate Tooling Validation Pass
Contact our global tool engineering division today with:
- Your current ISO model requirements (e.g., CCGW 09T304)
- Your exact workpiece material (e.g., CFRP or Al-Si Castings)
- Your current cutting bottleneck (e.g., edge chipping or built-up edge)
Our laboratory will instantly activate your evaluation program: receive a dedicated trial batch of our advanced full-face inserts at direct factory wholesale cost, with 100% of the sample evaluation fee fully credited back to your balance upon your first commercial batch order.
[ Contact Our Global Tooling Desk & Request Your Custom PCD Quote Now ]
FAQ
Q: What is a PCD insert and what materials can it machine?
A: A PCD (Polycrystalline Diamond) insert is a cutting tool element consisting of an HPHT-sintered polycrystalline diamond layer on a tungsten carbide substrate, mounted in a standard ISO tool holder for CNC turning, milling, or boring operations. PCD inserts machine non-ferrous and non-metallic materials: aluminum alloys (including high-silicon grades such as A390), copper and brass, CFRP and GFRP composites, graphite electrodes, ceramics, and natural stone. They are not used on steel or cast iron – carbon from the diamond diffuses into iron at cutting temperatures, causing rapid chemical wear. In aluminum machining, PCD inserts achieve Ra ≤0.2 μm surface finish and tool life 50-100x longer than uncoated carbide.
Q: What is the difference between full-face PCD inserts and brazed-tip PCD inserts?
A: Full-face PCD inserts have a continuous HPHT-sintered diamond layer across the entire cutting face – there is no internal boundary between diamond and carbide within the active cutting zone. Brazed-tip inserts bond a small PCD segment to a carbide base using vacuum brazing. The brazed joint weakens above ~800 °C under vibration, causing tip delamination at high cutting speeds or during interrupted operations. Full-face inserts permit higher cutting speeds (Vc) and feeds (fz) without risk of sudden tip failure, and allow full utilization of all cutting edges without the depth-of-cut restriction imposed by the brazing line. For standard finishing operations at moderate parameters, brazed-tip inserts remain a cost-effective choice.
Q: How do I select the correct PCD insert ISO geometry for my application?
A: ISO insert geometry selection for PCD follows the same CCMT/CCGW/DCGW logic as carbide inserts, with additional consideration for approach angle and insert strength:
CCGW (80° rhombic) for external turning and profiling of aluminum bars – most common general-purpose choice.
DCGW (55° rhombic) for profiling and copying with narrow clearance.
TCGW (60° triangle) for general turning and facing with three usable edges.
WCGW (80° trigon) for interrupted cuts in aluminum castings – maximum edge strength.
SCGW (90° square) for face milling and shoulder milling.
Additionally, specify the PCD grain grade based on material: sub-micron for mirror-finish aluminum and optics; medium for CFRP; coarse for stone and abrasive ceramics. Contact Uking Diamond with ISO model, workpiece material, and current cutting parameters for a specific grade recommendation.
