Parameters for Diamond Polishing Cutter - Karat

Parameters for Diamond Polishing Cutter - Karat

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Parameters for Diamond Polishing Cutter



The monocrystalline diamond (MCD) which is attached to a carbide

shank consists of pure carbon and is extremely resistant to

wear. Although it has been produced synthetically, it has the same



like a natural diamond. This




material ensures

Parameters glassy polishing Polishing edges. It center-cutting for Cutter

and Diamond cuts sidewards Polishing Cutter

Polishing Cutter


as General: well as downwards.

Polishing Cutter

General: The monocrystalline diamond (MCD) which is attached to a carbide

Fields The car-monocrystalline shank of Application: consists of diamond pure carbon (MCD) and which is extremely is attached resistant to a car-


ached to a

ely resistant bide This wear. to tool shank Although is used consists it for has polishing of been pure produced carbon edges and and synthetically, pockets is extremely of it any has resistant contour the same to in

it has the

acrylic. wear. characteristics same Although A cutting like it edge has a natural been

or pocket

produced diamond. that has

synthetically, This been ultra-hard milled

it has

is material a



same ensures

characteristics en-

glassy polishing like a natural edges. diamond. It is center-cutting This ultra-hard and cuts material sidewards en-

rd material


cuts sidewards as sures well glassy downwards. polishing edges. It is center-cutting and cuts sidewards





as downwards.


Fields • This of Application:

tool is not suitable for milling. You should remove between

of is Application: used 0.04 mm for polishing and 0.06 edges mm of and the pockets material of in any each contour working

f any contour This acrylic. in tool cycle. A is cutting used for edge polishing or pocket edges that and has pockets been milled of any is a contour sufficient in

Fields This tool


ed is a sufficient preparation.

acrylic. • If vibrations A cutting edge should or occur pocket at that higher has been rotational milled speeds, is a sufficient please

reduce the rotational speed stepwise by 1,000 RPM – and reduce

for Machining:

also the feed rate accordingly – until you have reached a




Hints • vibration-free This for Machining:

tool is not running. suitable for milling. You should remove be-

This Tip: You tool 0.04 can is mm not polish and suitable your 0.06 for workpieces mm milling. of the material in You several should in steps each remove working if a fine be-

Polishes your acrylic edges and pockets to a high gloss

Polishing Graver

uld remove • be-tweein

each working cycle. tween polishing 0.04 step mm does and not 0.06 bother mm of you. the For material instance each you can working polish

If vibrations your 10 mm should thick occur material higher with a rotational cutting edge speeds, length please of 4

• cycle.

l speeds, please • reduce mm If vibrations in three the rotational should steps. So occur speed you at do stepwise higher not have rotational by to 1,000 use a RPM speeds, polishing – and please cutter

with also the a the cutting rotational feed edge rate speed length accordingly stepwise of 10 – mm until by which 1,000 you have is RPM much reached – and more re-

a expensive.


RPM – and re-reduchave reached a duce vibration-free also the running. feed rate accordingly – until you have reached a

Other • vibration-free Tip: Important You can Hints: polish running. your workpieces in several steps if a fine






can polish





ensure that




metal chips



if a



touch with


the cutting

your acrylic

edge during

edges and






a high gloss

l steps if a fine polishing step does not bother you. For instance you can pol-


Some laser Polishes


tool your


measuring acrylic edges

not bother devices and

you. do pockets

For not instance

recognize to a high


the gloss




mm your in the three 10

automatically, Polishes your so acrylic they edges return and wrong pockets tool to lengths. a high gloss

ce you can pol-

your 10 mm thick material with a cutting edge length of 4


dge length of 4

adjust tool

mm steps. manually

thick So material you in such do not with

a case. have a cutting to use edge a polishing length of cutter

The with diamond in three a cutting steps. is regrindable edge So you length do for of not several 10 have mm times.



a polishing cutis

much more

mm to which use


a is polishing much offer this more cutter

with a cutting edge length of 10 mm which is much more expensive.

service expensive. on request. Please allow approximately 14 days for this




Other Important Hints:

Other • Do Important not process Hints: metal and ensure that no metal chips get in touch with the cutting edge during the working process.

l chips get in • touch Do Some not with laser process the tool cutting metal measuring edge and ensure during devices that the do working not metal recognize process. chips the get diamond in touch with automatically, the cutting so edge they during return the wrong working tool lengths. process. Please

gnize the diamond • adjust Some automatically, laser the tool manually measuring so they such devices return a case. wrong do not tool recognize lengths. the Please diamond automatically, so they return wrong tool lengths. Please

• adjust The diamond the tool is manually regrindable such for several a case. times. We offer this service on request. Please allow approximately 14 days for this

We offer this • service. The diamond request. is regrindable Please allow for approximately several times. 14 We days offer for this this service on request. Please allow approximately 14 days for this


Please note...

In order to achieve best results with your new precision tool for a long time, you should set your tool parameters according to the following

data. However, whether it is actually possible to work with these theoretically determined values for feed rate and rotational

speed depends on the interaction of a number of factors. Thus we cannot assume liability for the calculated values. Among others, the

following factors determine the machining process:

Please note...

• additional cooling with compressed air or lubrication?

• Please power/maximum note... rotational speed of the spindle

• minimum/maximum feed rate of the CAM system

In • order controller to achieve features best (look-ahead results with your path new calculation, precision etc.) tool for a long time, you should set your tool parameters according to the following

time, • order stiffness you data. to achieve should However, of the set best machine. your whether results tool with parameters is your actually new according possible precision to tool the work for fol-

with a long these time, theoretically you should determined set your tool values parameters for feed according rate and to rotational the fol-

tool for a long In

o work with these speed lowing theoretically depends data. However, on determined the interaction whether values it of is for a actually number feed rate possible of factors. and rotational work Thus with we cannot these theoretically assume liability determined for the calculated values for values. feed rate Among and others, rotational the

rs. Thus we cannot speed following assume depends factors liability on determine the for interaction the calculated the machining of a values. number process: Among of factors. others, Thus the we cannot assume liability for the calculated values. Among others, the

following • additional factors cooling determine with the compressed machining air process: or lubrication?


• power/maximum additional cooling rotational with compressed speed of air the or spindle lubrication?

• minimum/maximum power/maximum rotational feed rate speed of the of CAM the spindle system

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• controller minimum/maximum features (look-ahead feed rate of path the calculation, CAM systemetc.)


• stiffness controller of features the machine. (look-ahead path calculation, etc.)

Karat • Nederland stiffness of the B.V. machine. l Postbus 10040 3004 AA Rotterdam l l Overschieseweg 87 3044EH Rotterdam


T: +31 (0)10 245 26 30 l F: +31 (0)10 245 26 40 l



Tool Data/Formula

Tool Data:

Feed rate f z : 0,03 mm/cutter tooth

rotational speed n: min. 18,000 RPM

Formula for Calculating the

Feed Rate:

v f [mm/min] = f z [mm] x n [RPM]


v f Feed rate

f z Feed rate per cutter tooth

n Rotational speed of spindle

Hints for the Calculation

As the diamond can work with very high cutting speeds

(rotational speed of up to 80,000 RPM) which can be

reached by only few spindle types, you can work theoretically

with the maximum rotational speed of your

spindle. However, we do recommend to stay approximately

20% below the maximum rotational speed in order

to reduce the spindle load. Moreover, the spindle

runs smoother then. Please ensure, however, that the rotational

speed amounts to at least 18,000 RPM. Starting

from the rotational speed, the feed rate is being calculated


Sample Calculation:

You want to process the material with a rotational speed

of 24,000 RPM. The tool data indicates a feed rate f z of

0.03mm per cutter tooth. Using the above formula, you

can calculate then the feed rate of your machine:

Feed rate v f : 0.03 mm x 24,000 RPM

= 720 mm/min = 12 mm/s

Overview of Feed Rates

Rot. Speed Feed Rate Feed Rate

in RPM in m/min in mm/s

18,000 0.54 9

24,000 0.72 12

30,000 0.90 15

36,000 1.08 18

42,000 1.26 21

48,000 1.44 24

54,000 1.62 27

60,000 1.80 30

80,000 2.40 40

Karat Nederland B.V. l Postbus 10040 l 3004 AA Rotterdam l Overschieseweg 87 l 3044EH Rotterdam

T: +31 (0)10 245 26 30 l F: +31 (0)10 245 26 40 l

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