The DNM100 is a solid polycrystalline diamond (PCD) end mill engineered for high-efficiency precision machining of non-ferrous metals and non-metallic composite materials. By combining an ultra-hard diamond cutting edge with a purpose-designed edge geometry, the DNM100 delivers exceptional wear resistance, dramatically extended tool life and a superior machined surface finish-making it the ideal milling solution for manufacturers who cannot afford tool changes mid-batch or surface-quality variation on critical parts.
Key Features & Benefits
Ultra-hard PCD cutting edge
polycrystalline diamond provides far higher hardness and wear resistance than tungsten carbide, sustaining sharp cutting edges over long production runs.
Extended tool life
in abrasive non-ferrous and composite workpieces, the DNM100 routinely outlasts carbide equivalents many times over, reducing tool-change downtime and per-part cost.
Superior surface quality
the unique edge design produces smooth, low-roughness machined surfaces, minimizing or eliminating secondary finishing operations.
Dimensional consistency
stable cutting performance keeps tight tolerances (straightness, flatness, perpendicularity) intact across long batches.
Dry-cutting capable
supports dry machining in many applications, simplifying coolant management and enabling cleaner processing of materials such as graphite and composites.
Versatile processing range
suitable for roughing, semi-finishing and finishing of copper, aluminum alloys, graphite and composite materials.
Technical Specifications
|
Parameter |
DNM100 Series |
|
Product series |
DNM100 |
|
Tool type |
Solid PCD end mill |
|
Cutting material |
Polycrystalline Diamond (PCD) |
|
Workpiece materials |
Cast aluminum, aluminum-silicon alloy, copper, cemented carbide, graphite, GFRP, CFRP, reinforced plastics, wood |
|
Machining operations |
Face milling, side milling, roughing, semi-finishing, finishing |
|
Example geometry |
D8 × R0.2 × 15 × 75 × d10 (diameter × corner radius × flute length × overall length × shank diameter) |
|
Example order code |
DNM100-RS2-08002 |
|
Customization |
Multiple diameters, corner radii, flute lengths and shank sizes available; custom geometries on request |
Application case
The DNM100 is purpose-built for workpieces where carbide tools wear too quickly or fail to deliver the required surface quality. Typical machinable materials include:
Non-ferrous metals: cast aluminum, aluminum-silicon alloy (silicon-aluminum), copper and copper alloys, cemented carbide
Composite materials: glass-fiber reinforced plastics (GFRP), carbon-fiber reinforced plastics (CFRP), reinforced / intensified plastics
Non-metallics: graphite, wood and similar engineered non-metallic materials
Supported operations cover face milling, side milling, roughing, semi-finishing and finishing, making the DNM100 a flexible choice across a wide range of part features.
Industries Served
Aerospace
structural composites, aluminum airframe components
Automotive
engine housings, transmission parts, lightweight aluminum and composite assemblies
3C electronics (consumer / computers / communications)
precision aluminum and graphite parts
General machinery
precision components requiring tight tolerances
Wind power
precision machining of composite and metal structural parts
Any industry with high
precision machining requirements
Application Case Study - Vortex Shell (Dynamic & Static Disk)
|
Specification |
DNM100-RS2-08002 |
|
Geometry (Grade) |
D8 × R0.2 × 15 × 75 × d10 |
|
Workpiece material |
Aluminum alloy |
|
Cutting speed |
Vc = 200 m/min |
|
Feed per tooth |
fz = 0.05 mm/z |
|
Depth of cut |
ap = 0.04 mm |
|
Cooling method |
Dry cutting |
|
Cutting method |
Face milling + side milling |
|
Tool life |
1,675 pcs |
|
Process requirements |
Straightness 0.005 mm, perpendicularity 0.008 mm, no surface color difference, no chatter marks |
Recommended Cutting Parameters (Starting Values)
The values below are general starting points for the DNM100 in common workpiece materials. Always validate on your own machine and workpiece geometry, and adjust based on rigidity, clamping and surface-finish targets.
|
Workpiece material |
Cutting speed Vc (m/min) |
Feed per tooth fz (mm/z) |
Coolant |
|
Aluminum alloy |
~200 |
~0.05 |
Dry / air |
|
Copper / copper alloy |
150–300 |
0.03–0.08 |
Dry / air |
|
Graphite |
200–400 |
0.03–0.10 |
Dry / dust extraction |
|
CFRP / GFRP composites |
100–300 |
0.03–0.08 |
Dry / air |
|
Reinforced plastics |
100–300 |
0.03–0.08 |
Dry / air |
Why Choose a PCD End Mill?
Polycrystalline diamond (PCD) is one of the hardest cutting materials available, made by sintering diamond grits under high pressure and high temperature. Compared with tungsten carbide, PCD offers:
Far higher hardness and wear resistance, so the cutting edge stays sharp for longer in abrasive materials;
Lower coefficient of friction, which reduces built-up edge and improves surface finish, particularly on sticky materials like aluminum and copper;
High thermal conductivity, helping dissipate heat from the cutting zone;
Lower per-part cost in volume production, despite a higher unit price, thanks to longer tool life and fewer changeovers.
Note: PCD is not recommended for ferrous metals (steel, cast iron) because diamond reacts chemically with iron at elevated cutting temperatures. For ferrous materials, use CBN (cubic boron nitride) or carbide tooling instead.
How to Select the Right DNM100 Geometry
Diameter (D)
choose based on the smallest feature width and the required stock removal rate.
01
Corner radius (R)
a small radius (e.g. R0.2) improves surface finish and reduces corner chipping on composites; a larger radius strengthens the edge for roughing.
02
Flute length (l)
keep as short as possible while reaching the required depth to maximize rigidity.
03
Overall length (L) & shank diameter (d)
match the tool-holder and machine spindle; a larger shank improves stiffness for deep cavities.
04
Operation type
select geometry suited to roughing, semi-finishing or finishing per your process plan.
05
Not sure which geometry fits your application? Send us your drawing or machining requirements and our engineers will recommend the optimal DNM100 specification.
Frequently Asked Questions
Q1: What materials can the DNM100 PCD end mill machine?
A: The DNM100 is engineered for non-ferrous metals (cast aluminum, aluminum-silicon alloy, copper, cemented carbide) and non-metallic composites such as glass-fiber reinforced plastic (GFRP), carbon-fiber reinforced plastic (CFRP), reinforced plastics, graphite and wood.
Q2: What is the difference between PCD and carbide end mills?
A: PCD (polycrystalline diamond) is significantly harder and more wear-resistant than tungsten carbide. In abrasive non-ferrous and composite materials, a PCD end mill typically lasts many times longer than a carbide tool while producing a better surface finish. PCD is not suitable for ferrous metals (steel/iron) because diamond reacts with iron at cutting temperatures.
Q3:Can the DNM100 be used for both finishing and roughing?
A: Yes. The DNM100 is suitable for roughing, semi-finishing and finishing operations on copper, aluminum alloys, graphite and composite materials.
Q4: What cutting parameters are recommended for aluminum?
A: For aluminum alloy, a typical starting point is cutting speed Vc = 200 m/min, feed per tooth fz = 0.05 mm/z, and depth of cut ap = 0.04 mm under dry cutting. Actual parameters should be adjusted based on workpiece geometry, machine rigidity and the specific DNM100 geometry selected.
Q5: Do you offer custom geometries and dimensions?
A: Yes. The DNM100 series is available in multiple diameters, corner radii, flute lengths and shank sizes. Custom geometries can be produced on request to match your specific application. Contact us with your drawing or machining requirements.
Request a Quote / Technical Consultation
Looking for a reliable PCD end mill for aluminum, copper, graphite or composite machining? The DNM100 delivers the tool life, tolerance control and surface finish your production demands. Contact us today with your workpiece material, drawing and target parameters for a tailored recommendation and quotation.
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