PCD shank tools

Shank bar

The bar is matched on the turned envelope, the widest diameter the lathe has to leave, never on the cutting diameter.

• Shank 42CrMo4 QT steel bar0.26 lengths

  Ø16 x 3150mm, cut 83mm per tool

  37 tools per bar and 1 bar for the order. Offcut 79mm goes back to stock.

  42CRMO4-QT-16in your stock

• Blank cut from the bar10 off

  81mm blank, 83mm of bar used with the saw kerf

  Turned to the envelope, then ground to the shank tolerance.

PCD tips

Each tip is its own blank, seat and braze.

• Cutting tip20 off

  25.75 x 4 x 1.6mm, 10 µm

  2 per tool, cell 25.9 x 4.15mm with the grind stock.

PCD blanks

Tips are nested on round discs at the kerf of the cutting method, grouped by grade, thickness and layer.

• PCD blank, 10 µm, 1.6mm0.72 off

  Ø74mm, 0.5mm layer

  20 tips on 1 disc, 52.8 per cent of the usable area.

  E6-CTB010-74-16in your stock

Braze

Braze foil is cut to each seat, with flux.

• Braze alloy, grams6.05 off

  0.605g a tool, Ag 449 tri-foil, 0.3mm

  Brazed at 705 degrees.

• Braze flux10 off

  One charge of flux a tool.

Operations

Minutes for the whole order, with the setup counted once.

• 10 Saw bar to length15 min
• 20 Turn shank, neck and body90 min
• 30 Mill flutes, gullets and tip seats185 min
• 40 Cut tips from the disc105 min
• 50 Clean and fixture30 min
• 60 Braze tips50 min
• 70 Blast and clean30 min
• 80 Grind shank to tolerance60 min
• 90 Erode or grind PCD edges245 min
• 100 Balance tool50 min
• 110 Inspect and laser mark50 min

What this take-off assumes

• Tips are cut by wire EDM with a 0.32mm kerf and a 1mm rim margin on every disc. Both are engineering estimates until you enter your own.
• Each tip cell carries 0.15mm of grind stock on the cutting edge and the tool end edge, which the edge grinder removes.
• The bar is matched on the turned envelope of Ø12.7mm.
• The envelope is the shank plus 0.2mm of grind stock, the head body and the neck, plus 0.5mm of clean up.
• Each tool uses 83mm of bar: the length, 2mm of saw kerf and 0.5mm of facing at each end.
• An offcut of 40mm or more goes back to stock.
• Braze alloy is the seat area times the foil thickness times 1.1 for fillet and waste, at 8.9 g/cm3.
• Routed minutes are engineering estimates. Your own times replace them in Costing settings.
• The wire EDM kerf is 0.32mm, half on each side of every cell, so neighbouring cells sit a full kerf apart.
• The rim margin is 1mm inside the usable diameter of the disc.
• Tips are placed in quarter turns. Each cell is placed by its rotated bounding box.
• Tips are placed three ways, by area, height and width, and the layout with the fewest discs is kept.
• The last disc of a group keeps its remnant when the smallest cell fits in it.
• Shank bar cost is taken from stock row 42CRMO4-QT-16, an example row, so it is modelled until you enter your own cost.
• PCD blank cost is taken from stock row E6-CTB010-74-16, 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.