Tools

The process of shaping the PCD/CBN materials for part application is completed by wire electrical discharge machining (EDM). Wire EDM machines use a thin wire to cut with electricity, with the wire advancing into the hard metal part as if it was a slow-motion saw blade. But the wire never touches the metal.

The thousands of electrical sparks emitted through the wire melt or vaporize the metal away. Deionized water flushes the remaining debris away and leaves a smooth cut surface. With a positioning accuracy of +/- .0004 inches, this type of cutting can easily machine complex and precision components into near net parts needing minimal – if any – finish grinding. The heightened accuracy and precision of this process influences the entire machining process using the finished ACT tool. A part that is manufactured for use in making a precision tool will define exactly how much material is taken off in the grind process of machining parts and can be a determining factor in reducing the amount of the grind and the stress it puts on the equipment. It is an integral part in the quality and total cost of a product.

 

Meeting Your Challenges

With over 50 years of experience in manufacturing standard carbide brazed tools, we have taken the knowledge we have gained working with equipment, technology and materials and have applied it to our production process. Production equipment has been tailored (modified) to enhance the intricacy of cutting tight corners, patterns and cuts. Wire cut EDM equipment is run by CNC (computer numerically controlled) instruments which can control the wire on a three dimensional axis to provide greater flexibility in meeting the challenges of machining precision tools. In the hands of a skilled operator, the equipment performs in perfect synchrony with the programmed data.

Any additional finishing of the segmented PCD/CBN component is then perfected using diamond grinding. This process produces a smooth, even edge and finish and provides a component of the exact size and cut needed for the precision tool.

Based on the specifications of the tool, the segment of PCD or CBN is accurately placed on the desired carrier, either an insert or a tool shank. The process of induction brazing joins the segment of PCD/CBN with the carrier. ACT selects C2 grade tungsten carbide steel for its wettability and hardness properties and high cobalt content. Under extreme heat – targeted on the placement of the segment – the binder of silver/copper melts and spreads into the geometric pattern of the diamond strata of PCD and the granular particles of CBN segments creating the joint between the tool carrier and the insert/tip. Once the silver/copper reaches its maximum fill, a chilling process quickly brings the temperature down to solidify the jointed materials.

The results are a precision tool that will cut accurately, is highly abrasion resistant, improves production processes and reduces overall production costs. Induction brazing, in the hands of a skilled operator, becomes an art of accuracy and precision. Highly qualified with intense training and years of experience, the artisan creates a tool of perfection.

 

Speed, Accuracy, Consistency

Induction brazing has the advantages of speed, accuracy and consistency. With faster heating cycles, targeted heat application and rapid cool down process; induction brazing provides better joint quality, and consistent repeatable results.

Selective heating

Induction brazing is targeted to very small areas with tight production tolerances. Only the segment of PCD and CBN to be jointed are heated. Heating these very small areas eliminates repeated exposure of intense heat to the fixtures and increases the life of the fixtures.

Better quality joints

When heated to an exact temperature and rapidly cooled, the filler is prevented from creeping into areas it shouldn’t. This creates clean concise joints.

Fast heating cycles

Induction heating cycles achieve exact heating and cooling temperatures quickly and allow for more parts to be processed and less heat consumption in production.

Consistent results

Skilled operators control the outcome of consistent quality results. Variables like time, temperature, fixturing and part positioning are controllable and repeatable.

Distributors and dealers can find a full inventory of precision PCD/CBN tools along with a full line of standard brazed carbide tools in our facility in Canton, Ohio, USA. Orders can be picked and shipped within 24 hours of ordering.