PCD profile cutters

Body blank

The steel billet the body is machined from: hub, rim and seats.

• Cutter body blank1 off

  Ø123 x 39mm billet

  3.64 kg each, machined to Ø116.7 body with 6 seats

PCD knives

Blanks wire cut from PCD discs, then the form eroded.

• PCD knife, straight jointing6 off

  34.8 x 6.7mm blank, 1.6mm thick

  6 per cutter, form edge 34.2mm

• PCD disc, Ø58mm usable, 0.5mm layer1 off

  8 knife blanks per disc for the whole order

  PCD-58-16-052 weeks£95.00 / each

Operations

• Braze attachments6 off

  One braze per knife.

• Form erosion, per knife edge205 off

  Millimetres of form edge across the order.

What this take-off assumes

• Body blank charged as the cylindrical billet, Ø123 x 39mm (6mm machining margin) at 7.85 g/cm3.
• Knife blanks allow 0.6mm along the length for finish grinding and 0.5mm on the height for the braze seat, over a knife height of 6.2mm (a flat form plus 4mm resharpening area).
• Disc yield is geometric: a 58mm usable disc gives 8 blanks at 0.25mm wire EDM kerf and 82 per cent packing. No supplier publishes a tips-per-disc figure.
• One braze operation per knife. Knives are permanently brazed: a profile cutter is a fixed tool once built, not an insert system.
• The 15 degree shear makes each knife blank 34.2mm along the helix, against the 33mm cutting width it covers.
• Each knife is a straight chord of the helix, so its edge is eroded with a 0.16mm crown to sweep the 125mm cutting circle. The crown is carried in the knife height.
• PCD disc cost is taken from stock row PCD-58-16-05, an example row, so it is modelled until you enter your own cost.

Stock that covers this size

The stock below is the example list the preset ships with. Load your own and the take-off matches against what you actually hold.