Application areas of PCBN Inserts

Suitable for high-speed and ultra-high-speed cutting technologies

PCBN Inserts are most suitable for high-speed cutting of cast iron, hardened steel and other materials. 

From the relationship between the tool flank wear and the cutting distance when the PCBN Inserts cuts cast iron and hardened steel, it can be seen that when the cutting speed exceeds a certain limit, the higher the cutting speed, the lower the PCBN Inserts flank wear speed, that is, high speed. 

The tool life undercutting is high, especially suitable for modern high-speed cutting.

The best tool material for hard machining technology

Finishing of hardened hardware (hardness HRC55 and above) is usually done by grinding. However, with the development of tool materials and the improvement of machining accuracy of lathes (especially CNC lathes), hard cutting is used instead of grinding for the completion of parts. 

The finishing of machine tools has become a new finishing method. This method of turning instead of grinding has the following advantages:

(1) Improve processing flexibility, break through the limitation of grinding wheel grinding, and can process workpieces with different geometric shapes by changing cutting edges and cutting methods;

(2) With the development of the industry, the environmental protection problems in cutting processing are becoming more and more serious, and the waste liquid and waste generated by grinding processing are becoming more and more difficult to deal with, because they are harmful to the human body, while hard cutting does not need to add coolant to avoid generation of waste liquid;

(3) The processing cost can be reduced; the cutting efficiency is high, the processing time is short, and the equipment investment cost is small,

(4) The energy consumed by cutting the same volume is only 20% of that of grinding, so less cutting heat is generated, the machined surface is not prone to burns and tiny cracks, and it is easy to maintain the integrity of the workpiece and the surface properties of the workpiece;

(5) At the same metal removal rate, hard cutting is more energy efficient than grinding.

The commonly used tool materials for hard cutting are ceramics, coated inserts and PCBN Inserts materials, but hard turning should be carried out at a higher speed (above 1000m/min), and PCBN is the best tool material variety. 

For example, in the fork processing of automobile gearbox synchronizer (material is 20CrMnTi, hardness is HRC58~62), the efficiency is increased by more than 4 times and the processing cost is reduced to 1/3 to 1/3 of the original grinding process. Half.

Suitable for automated machining and machining of difficult-to-machine materials

PCBN Inserts have high hardness and wear resistance, and can machine high-precision parts (small size dispersion) at high cutting speeds for a long time, greatly reducing the number of tool changes and tool wear compensation downtime. 

Therefore, it is very suitable for CNC machine tools and processing equipment with a high degree of automation, and can give full play to the high efficiency of the equipment.

In the application of difficult-to-machine materials, PCBN Inserts also show excellent performance, such as the machining of surface spray welding (coating) materials, machining with other material tools, the tool life is extremely low, and cannot be machined by grinding methods, 

while PCBN is The only suitable tool material; another example is high-alloy wear-resistant cast iron used in petroleum power station equipment. 

The use of PCBN Inserts improves the cutting efficiency by more than 4 times compared with carbide tools, and the cost per tool is reduced by 1/5 of the original. In addition, in the cutting of sintered materials such as cemented carbide, PCBN Inserts also show good cutting performance.