PCD tooling for aluminum bore finishing

Begin with the component and the finish requirement

01

Identify the aluminum

Provide the alloy designation and silicon content. Note any inserts or other materials the cutting edge may encounter.

02

Define the bore geometry

Show the bore diameters, steps, depths and chamfers. Include the machining allowance and whether the feature is blind or through.

03

Specify the acceptance criteria

State the dimensional tolerance and required surface finish, together with the machine interface and available reach. These inputs define the tool review.

A stepped-bore application in the catalogue

The catalog supplement includes a custom PCD form reamer for finishing a stepped bore in an aluminum housing. The catalogue records the following tool and application requirements.

H7 and Ra 2 μm are the requirements listed for this example; they are not presented as measured results. See PCD tooling in the catalog supplement (PDF).

Tool geometry and drawing review

DELEVEL lists form reamers, step reamers and other PCD tooling made to specification. The bore profile, interface and access need to be reviewed together. A drawing is provided for approval before manufacture.

The photographs show PCD tool geometry. Refer to the approved drawing for the specified profile.

Information needed for an aluminum tooling enquiry

• Alloy designation, silicon content and any other materials in the cut.
• Component drawing with bore diameters, step dimensions, depths and machining allowance.
• Dimensional tolerances, surface finish and inspection requirements.
• Machine, spindle interface, holder and available reach.
• Batch size, expected repeat demand and the current process, if one is in use.

Use the PCD product page for the wider tool family, or custom tooling for other drawing-led requirements.