Cutting parameter determination in the hard turning of G60 grade WC-Co with PCD inserts

This study investigates the feasibility of hard turning with polycrystalline diamond (PCD) inserts as a technical alternative to grinding in the machining of G60 grade WC-Co hard metal rolls. Using Design of Experiments (DOE), 36 tests were conducted varying the cutting speed (20, 25, and 30 m/min) and feed rate (0.05, 0.10, and 0.15 mm/rev), with a constant depth of cut (0.1 mm), using PCD5610 and PCD5632 inserts. Results showed that the feed rate was the most influential factor on surface roughness, followed by cutting speed, with statistically significant interactions between factors. The best surface finish (Ra ≈ 0.21 μm) was achieved with the PCD5610 insert at 30 m/min and 0.05 mm/rev, although with greater wear and lower productivity. The PCD5632 insert demonstrated more stable performance under intermediate conditions. The study demonstrates that hard turning with PCD is a technically viable alternative to grinding, offering significant benefits in surface finish, production efficiency, and process sustainability. Replacing grinding by hard turning of WC-Co rolls in G60 grade. DOE-based optimization of cutting parameters for finish and tool wear. Comparative evaluation of PCD 5610 and 5632 inserts on WC-Co machining. Significant Ra reduction using PCD 5610 at 30 m/min and 0.05 mm/rev.