Long-Term Performance Analysis of PCD Tools in the Milling of Aluminium Alloy Components in a Manufacturing Context

Aluminium alloy components are gaining traction in the automotive industry due to their lightweight properties, contributing to improved fuel efficiency and reduced emissions. Many of these components demand specific surface roughness profiles achieved through milling operations. However, excess material from upstream processes—such as flash remaining after demoulding —presents challenges for the machining process. These irregularities, combined with stringent demands for specific roughness, burr-free edges, and flatness, require careful selection of tool microgeometry, tool grade, and cutting parameters. Nonetheless, research concerning the behaviour of PCD tools when machining aluminium alloys remains limited, and existing studies often fail to address the complexities of high-volume production. This study investigates polycrystalline diamond (PCD) tool performance in high-speed milling of aluminium components through an eight-month production analysis comparing PCD grades and tool microgeometries. The research reveals that medium-sized grains in PCD tools lead to superior surface quality and a 22% longer tool life. Tools with larger tip radii (0.09 mm versus 0.06 mm) demonstrated significantly higher performance, reducing burr formation by 20% while maintaining lower surface roughness values. Insert height positioning emerged as a critical factor, since reducing deviations between insert heights substantially extended tool life and ensured consistent surface roughness. The findings provide practical criteria for PCD tool selection and tool microgeometry, directly impacting cost-efficiency in high-volume automotive component manufacturing.