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PCD and PCBN tools are the workhorses of modern precision machining.
PCD (Polycrystalline Diamond) – for cutting non-ferrous metals, composites, and abrasive materials
PCBN (Polycrystalline Cubic Boron Nitride) – for cutting hardened steels and cast irons
These tools are incredibly hard, wear-resistant, and long-lasting. But they require specialized grinding and polishing to achieve their full potential.
A poorly polished PCD or PCBN tool will have a rough cutting edge, reduced tool life, and poor surface finish on the workpiece.
The solution? A ceramic bond diamond grinding wheel with 400 grit.
In this article, we'll explain why this wheel is the right choice for PCD and PCBN polishing, how to use it effectively, and what results you can expect.
PCD and PCBN are among the hardest materials used in manufacturing.
| Material | Hardness (HV) | Abrasive Required | Polishing Challenge |
|---|---|---|---|
| PCD | ~6,000-8,000 | Diamond | Extremely hard – only diamond works |
| PCBN | ~3,000-5,000 | Diamond or CBN | Hard and brittle – requires fine control |
| Problem | Cause | Result |
|---|---|---|
| Rough cutting edge | Wheel too coarse or dull | Poor tool performance |
| Chipping | Too much pressure or heat | Damaged tool edge |
| Inconsistent finish | Wheel not true | Variable edge quality |
| Thermal damage | Excessive heat | Reduced tool life |
| Grit | Finish | Application |
|---|---|---|
| #100-200 | Rough | Rough shaping |
| #400 | Smooth | Polishing, finishing |
| #800+ | Mirror-like | Super finishing |
400 grit provides the optimal balance – smooth enough for a polished edge, yet efficient enough for production work.
The bond type matters as much as the grit.
| Bond Type | Characteristics | Suitability for PCD/PCBN Polishing |
| :--- | :--- | :--- | :--- |
| Ceramic / Vitrified | Hard, rigid, form-holding, cool cutting | ⭐⭐⭐⭐⭐ Best |
| Resin | Softer, self-sharpening, moderate form-holding | ⭐⭐⭐ Good |
| Metal | Very hard, long life, runs hot | ⭐⭐⭐ Acceptable |
| Electroplated | Single layer, short life | ⭐⭐ Not recommended for production polishing |
| Feature | Benefit for PCD/PCBN Polishing |
| :--- | :--- | :--- |
| Excellent form-holding | Maintains wheel geometry – consistent edge quality |
| Cooler grinding | Good heat dissipation – prevents thermal damage |
| Consistent performance | Uniform material removal – predictable results |
| Long life | Outlasts resin bonds in production settings |
| Sharper cutting action | Produces smoother finishes on superhard materials |
PCD is the hardest material used in cutting tools. PCBN is the second hardest.
| Abrasive | PCD | PCBN | Reason |
|---|---|---|---|
| Diamond | ⭐⭐⭐⭐⭐ | ⭐⭐⭐⭐⭐ | Hardest – cuts both materials efficiently |
| CBN | ⭐ | ⭐⭐⭐ | Not hard enough for PCD; OK for PCBN |
| Silicon Carbide | ❌ | ❌ | Not suitable |
| Alumina | ❌ | ❌ | Not suitable |
For polishing PCD and PCBN, diamond abrasive is required.
| Feature | Benefit |
|---|---|
| Extreme hardness | Cuts the hardest tool materials |
| Sharp cutting edges | Produces smooth, sharp tool edges |
| Low friction | Less heat – prevents thermal damage |
| Long service life | Consistent performance over many tools |
| Tool Type | Application | Polishing Requirement |
|---|---|---|
| PCD inserts |
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