Tooling News No.052

Global Support, Global Solutions.

SUMIDIA BINDERLESS

PCD Tools for Carbide and Hard Brittle Material Turning

NPD10/SUMIDIA DA90
Rev.2

SUMIDIA BINDERLESSNPD10SUMIDIA

Realises the ultimate inhigh-precision machining

DA90

The trump card for roughingof cemented carbide and hardbrittle materials

SUMIDIA BINDERLESS (NPD10) Small Diameter Boring Bars

Introducing the DABX series Ideal for high-precision machining of small diameters (ø3mm and up)

SUMIDIA BINDERLESSSUMIDIANPD10/DA90
 Application Range (Cemented Carbide)

Cutting Speed vc (m/min)30
SUMIDIA BINDERLESS

20NPD10NPD10For Finishing

Displays outstanding wear resistance undercemented carbide ﬁnishing conditions,suppressing dimensional variation

SUMIDIA

1088HRALess thanand above 88HRA

DA90

DA90
Realises stable tool life in sinteredsurface machining of cemented carbide

0Depth of Cut ap (mm) 0.1

0.2

0.3

0.4

0.5

SUMIDIA BINDERLESS

NPD10Made from high-hardness nano-polycrystalline diamond,the pure diamond material used for the cutting edge has noanisotropy, unlike single-crystal diamonds.
It achieves extended tool life and machining accuracy superior
to conventional diamond tools when machining hard brittlematerials such as cemented carbide.

Ideal for ﬁnishing of hard brittle materials including cemented carbide
The outstanding wear resistance of nano-polycrystalline diamond enables high-precision
machining of cemented carbides

Superior dimensional accuracy maintained for a long time
Number of tool changes can be drastically reduced compared to conventional diamond
tools, enabling work efficiency to be improved and total costs to be reduced.

D Nano-polycrystalline diamond

D Hardness

Nano-polycrystalline diamond ispolycrystalline diamond that directly binds
nano-order diamond particles with highstrength without using any binders.
Harder than single-crystal diamond, it has
no cleavability, enabling machining of hardbrittle materials such as cemented carbide
and making new machining methods
possible.

Nano-polycrystalline
Ultra-hard with no anisotropy
DiamondSingle-crystal
DiamondHardness depends on crystal orientation

Conventional
PCD
Load 4.9N
050100Knoop Hardness HK (GPa)2150

SUMIDIA BINDERLESS/SUMIDIA

NPD10/DA90

 SUMIDIA Grade List
Grade

SUMIDIA BINDERLESSSUMIDIA

SUMIDIASUMIDIASUMIDIANPD10DA1000

DA2200DA150

DA90Structure
0.1μm

5μm

Diamond particles

5μm

5μm5μm* The white part of the image is the binderBinderQCoCo

Co

CoGrain Size (μm)

up to 0.05

up to 0.5

0.5550Content (%)

100

90 to 95

85 to 90

85 to 90

90 to 95

SUMIDIA

DA90

A polycrystalline diamond grade in which coarse diamondparticles have been sintered to form a dense structure.
The high diamond content, with high wear resistance, makes
it ideal for roughing of cemented carbide and hard brittlematerials.
Optimised design and mass production technology have beendeveloped, achieving the same performance as conventional
tools with higher cost-performance.

Ideal for roughing of hard brittle materials including cemented carbide
Stable tool life in sintered surface machining of cemented carbide and roughing of hard brittle
materials thanks to the outstanding wear resistance of nano-polycrystalline diamond

Uses SUMIDIA NF Insert
Optimised design and mass production technology have been developed, achieving the same
performance as conventional tools with higher cost-performance.

Inserts for machining of cemented carbide and hard brittle materials
newly stocked Applications of NPD10 and DA90 (Cemented Carbide Machining)
GradesSUMIDIA BINDERLESSSUMIDIANPD10DA90

Dimensional ToleranceBest

The ﬁrst recommendation is NPD10Tool Life (Wear Resistance)Best

ap = 0.2mm or above can also be used

Sintered surface machining ofcemented carbide

Impossible

Best

Machined Surface Quality

Best

The ﬁrst recommendation is NPD103

SUMIDIA BINDERLESS/SUMIDIA

NPD10/DA90
 NPD10 Wear Resistance Performance
Flank Wear Width (mm)Shows outstanding wear resistanceAfter Cutting 470m

After Cutting 130m

Conventional PCD






NPD10

D
DDDD

Cutting Distance (m)Conventional PCD(VB = 0.171mm)

NPD10(VB = 0.034mm)

Work Material: Cemented Carbide (87HRA) Tool: DCMW11T304RH
Cutting Conditions: vc=20m/min f=0.1mm/rev ap=0.1mm Dry

 NPD10 Machining Precision
No dimensional variation even after 1,100m of cutting30mm





Conventional PCD






NPD10
DD
D D D D D D D D D D D D D D D D D D D



Cutting Distance (m)Work Material: Cemented Carbide VC50 (87HRA)
Tool: DCMW11T304RH
Cutting Conditions: vc = 20m/min f = 0.1mm/rev
ap = 0.1mm Dry

Flank Wear Width (mm)Displays excellent wear resistance in roughing conditions

DA90

Conventional PCD

D



D



D





DD



D



30mm



Conventional PCD









NPD10
DDD
DDDDDDDDDDDDDDDDD       Cutting Distance (m)Work Material: Cemented Carbide VM30 (91HRA)
Tool: DCMW11T304RH
Cutting Conditions: vc = 20m/min f = 0.05mm/rev
ap = 0.05mm Dry

 DA90 Wear Resistance Performance



Cutting Distance (m)Work Material: Cemented Carbide VC50 (87HRA)
Tool: NF-DCMW070204
Cutting Conditions: vc = 20m/min f = 0.1mm/rev
ap = 0.2mm Wet

4

ø26mm

Internal Boring
Dimensional Variation (mm)ø50mm

External Turning
Dimensional Variation (mm)No dimensional variation even after 450m of cutting

SUMIDIA BINDERLESS Small Diameter Boring Bars

DABX series
 Features
Lineup of SUMIDIA BINDERLESS Small Diameter
Boring Bars for small-diameter machining(ø3.0mm, ø4.0mm)
Ideal for small-diameter turning, with a highrigidity shank shape and the excellent wear
resistance of nano-polycrystalline diamond* For internal boring of ø5mm or above, NPD10 inserts and cutting edge
indexable holders can also be used.
Refer to the chapter on "Boring Bars" in the General Catalogue fordetails.

Superior wear resistance maintains cutting edge sharpness for a long time

DABX series

After Cutting 4,000m

Machined Surface Roughness
Rz 2.82μm



200μm

ø10mm

DABX series
ø30mm

Max. Flank Wear Width (μm)

Wear resistance evaluation with cemented carbide (88HRA)

After Cutting 4,000m

   Cutting Distance (m)200μm

 Carbide Mold
30 pcs machining
equivalent

Minimal wear as of cutting distance 4,000m

Use of cutting reduces machining time and total costs
Switch from electrical discharge machining to cutting

Cemented Carbide G5 (88HRA) Header Former Mold
2.5 Times the Machining Efficiency
Machining Time

86min

(relative values)

Machining costs*

35min

Costs 25% reduced Cutting
 Electrical Discharge Machining PolishingElectrical Discharge +Polishing

Cutting + Polishing*Assuming ø4.0 o ø4.5 × L20 turning with machining costs at 3,500 JPY/h, calculating tool life at 30 units/pc

The switch from electrical discharge machining to cutting reduces polishing time
Machining efficiency 2.5x, total costs 25% reduced5

SUMIDIA BINDERLESS/SUMIDIA

NPD10/DA90
 Application Examples (Inserts)

Cemented Carbide VC40 (89HRA) Die Mold Cemented Carbide VM70 (84HRA) Die Mold
NPD10 reaches machining efficiency 4 times that ofcompetitors’ PCD, with stable dimensional tolerance as well

1520mm
ø8mm

10500.035
0.030
0.025
0.020
0.015
0.010
0.005



Competitor's PCD

30mm



ø8mm

Dimensional Variation (mm)No. of Workpieces (pcs)

NPD10 achieves 5 times the tool life ofcompetitors’ PCD

NPD10D
DDDDDDDDDDDDDDD

0200

400600Material Removal Volume (mm3)

NPD10 Competitor's PCD

Tool: CCMW04X104RH (NPD10) Internal Boring
Cutting Conditions: vc = 15m/min f = 0.015mm/rev ap = 0.07mm Dry

Tool: CCMW03X102RH (NPD10) Internal Boring
Cutting Conditions: NPD10 vc = 25m/min f = 0.05mm/rev ap = 0.05mm Dry
Competitors’ PCD vc = 5m/min f = 0.03mm/rev ap = 0.10mm Dry

Cemented Carbide VM30 (91HRA) Die Mold Alumina (99% pure)

100 Reduced33%500DA90+Grinding

0.120.10

Conventional PCD

0.08

ø50mm

Max. Flank Wear Width (mm)Machining Costs (%)

Machining costs reduced by 33% compared to conventional
NPD10 displays excellent wear resistancegrinding by using DA90 for roughing and NPD10 for ﬁnishing performance with alumina as well0.06 NPD100.04DD0.02DDDD0500

1,000

1,500

Cutting Distance (m)60mm

NPD10Tool: Roughing NF-CCMW060202 (DA90) Internal Boring
Finishing CCMW060202RH (NPD10) Internal Boring
Cutting Conditions : Roughing vc = 20m/min f = 0.10mm/rev ap = 0.10mm Dry
Finishing vc = 20m/min f = 0.02mm/rev ap = 0.02mm Dry

Tool: DNMA150408RH (NPD10) External Turning
Cutting Conditions: vc = 300m/min f = 0.03mm/rev ap = 0.01mm Wet

Cemented Carbide VC70 (85HRA) Die Mold Cemented Carbide VF10 (93HRA) Carbide Pin

No. of Workpieces (pcs)1025mm
5ø10mmNo. of Workpieces (pcs)

DA90 achieves 2 times the tool life of competitors’ PCD NPD10 achieves 6 times the tool life of competitors’ PCD

0DA90 Competitor's PCD

Tool: NF-CCMW04X102 (DA90) Internal Boring
Cutting Conditions: vc = 20m/min f = 0.075mm/rev ap = 0.1mm Wet







NPD10 Competitor's PCD

Tool: DCMW11T302 (NPD10) External Turning
Cutting Conditions: vc = 30m/min f = 0.01mm/rev ap = 0.1mm Dry6

SUMIDIA BINDERLESS Small Diameter Boring Bars

DABX series
 Application Examples (Boring Bars)

Cemented Carbide G5 (88HRA) Header Former Mold Cemented Carbide G5 (88HRA) Header Former Mold

DABX seriesDDDDD  Cutting Distance (m)Carbide Workpiece
30 pcs machining equivalent

Cemented Carbide G2 (91HRA) Header Former Mold
The DABX series displays excellent wear resistance in small-diametermachining of high-hardness cemented carbide as well

20mm




Able tocontinueD

ø4mm

DD DD  Cutting Distance (m)Tool: DABX035R-02 (NPD10) Internal Boring
Cutting Conditions: vc = 10m/min f = 0.05mm/rev ap = 0.025mm Dry

724mm
43%

 Reduction

90min


ø4mm

Machining Time(relative values)Machining Costs

20mm





Tool: DABX035R-02 (NPD10) Internal Boring
Cutting Conditions: vc = 10m/min f = 0.05mm/rev ap = 0.025mm Dry

Max. Flank Wear Width (mm)Machining efficiency improved by 3x or more throughswitching from electrical discharge machining tocutting in small-diameter machining of carbides




ø4mm

Max. Flank Wear Width (mm)

The DABX series displays excellent wear resistancein small-diameter machining of carbides as well

20min
Cutting Electrode Machining
DABX series Electrical DischargeMachining

Tool: DABX035R-04 (NPD10) Internal Boring
Cutting Conditions: vc = 10m/min f = 0.05mm/rev ap = 0.05mm Dry

SUMIDIA BINDERLESS/SUMIDIA

NPD10/DA90
 NPD10 Stock List

 DA90 Stock List

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SUMIDIA BINDERLESS Small Diameter Boring Bars

DABX series
SUMIDIA BINDERLESS
BrazedBinderless

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9

SUMIDIA BINDERLESS/SUMIDIA

NPD10/DA90
 Recommended Cutting Conditions
Work Material

Cutting Conditions
GradesClassiﬁcation

Hardness (HRA)

Our Grades

Cutting Speed vc (m/min)Feed Rate f (mm/rev)

Depth of Cut ap (mm)

VM,VC

40

88 or more

G5,D2NPD105-15- 20

0.03 - 0.05 - 0.07

0.03 - 0.05 - 0.07

VM,VC

70,60,50

83 to less than 88

G7,G6

NPD105-20- 30

0.03 - 0.10 - 0.20

0.03 - 0.10 - 0.20

VM,VC-

83 or more

G7,G6,G5,D2

DA90

5-20

- 30

0.03 - 0.10 - 0.20

0.03 - 0.10 - 0.50

Min. - Optimum - Max. Lubrication: Dry (NPD10) / Wet (DA90)

 Application Range for NPD10 and DA90

 Application Range for DABX series Boring Bars

Depth of Cut ap (mm)Depth of Cut ap (mm)DA90



Less than
88HRANPD10Less than88HRA

NPD10


88HRA and above



88HRA and above    Feed Rate f (mm/rev)

Feed Rate f (mm/rev)* Carbide shank holder is recommended for internal boring.

10

MEMO11

< SAFETY NOTES >Very hot or lengthy chips may be discharged while themachine is in operation. Therefore, machine guards,
safety goggles or other protective covers must beused. Fire safety precautions must also be considered.

Please handle with care as this product has sharp edges.
Improper cutting conditions or mis-handling of the tool
may result in breakages or projectiles. Therefore, please
use the tool within its recommended conditions.

When using non-water soluble cutting oil,precautions against ﬁre must be taken andplease ensure that a ﬁre extinguisher isplaced near the machine.

Hardmetal Division
Global Marketing Department : 1-1-1, Koyakita, Itami, Hyogo 664-0016, Japan
https://www.sumitool.com/globalR(2024.5)II 1810 TP/AK