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PCD insert and interrupted cut

jhearons

Cast Iron
Joined
Sep 16, 2003
Location
riverside, ca, usa
Has anyone experienced surface finish peculiarities when using PCD and making an interrupted cut? The finish was fine with carbide but is, for lack of a better word, “sandy” with the PCD insert. Switch was made for chip control reasons. The finish from PCD is beautiful everywhere except on the portion of the cut that is interrupted. Carbide didn’t show such a difference. Material is 6061-T6511 being cut with a DPMT 21.51. 5/8 carbide bar hanging out 4.125” from a split bushing (Sandvik Easy Fix). 780sfm (unbalanced part) and 0.004 ipr on a Multus B300W. Tool ran 100 pcs Op10 and 80 pcs Op20 without issue. New insert is great except for the finish at this one point.
 
After examining the insert under the microscope I saw a little build up on the carbide below the diamond. I backed it off on the grinder and voila, beautiful surface finish all around.
 
What was causing the buildup in the first place? Was it something that happened during setup/dial-in that won't happen in production?
 








 
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