Powder metallurgy uses metal powders as raw materials to produce finished parts via compaction and sintering. It boasts extremely high material utilization, and material properties can be precisely tuned to meet requirements such as high strength, high temperature resistance and corrosion resistance. Typical components include valve seats, partial transmission gears and synchronizer hubs for automotive engines.

This case covers finish turning of powder metallurgy cam discs with Worldia wiper-edge PCBN inserts.

In this case, the workpiece is a powder metallurgy cam disc. After compaction and sintering, the material easily develops internal pores and hard spots with uneven density, which aggravates abnormal tool wear during cutting.

To tackle this machining bottleneck, Worldia custom inserts adopt PN317 Insert Grade featuring excellent wear resistance and toughness. The nose radius is enlarged to properly strengthen the cutting tip and extend insert service life.

In addition, due to the surface roughness requirement of Ra 0.8, which is difficult to achieve with conventional tools on powder metallurgy materials, Worldia’s tooling solution adopts a wiper non-standard edge design. This provides a sharp cutting edge while also achieving a superior finishing effect, resulting in higher surface quality under the same cutting depth, spindle speed, and feed rate.

Worldia's customized tooling solution comprehensively improves the overall performance of the tool by scientifically selecting the most suitable insert grade, optimizing edge parameters tailored to the working conditions, and applying high-performance coating technology. This helps customers extend tool life, reduce tool changes and downtime, improve machining efficiency, lower unit costs, and ultimately enhance product competitiveness.

Data Source: Tool Test Report of Precision Tool Technology Department of Beijing Worldia Diamond Tools CO., Ltd.

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