Everyone recognizes the frustration of watching a carbide tool burn out within minutes when working with hardened steel. CBN inserts aim to remedy that situation since they provide cutting tools with which the machining world is able to cut materials where regular tooling fails. This publication provides information regarding how CBN inserts operate and where they deliver real value.
What are CBN inserts?
CBN inserts are cutting tools made of cubic boron nitride, the second-hardest material in the world after diamond. The hardness of CBN allows it to be effective when machining hardened steel, cast iron, and superalloys, which are known to wear down conventional tooling quickly.
It depends on the blade type, which is the right one for you. Whilst solid blades offer several cutting edges, tipped and brazed edges are more economical.
Where CBN Inserts Are Used
CBN inserts can be used in all professions related to hard and wear-resistant materials. Here are some of the most important applications.
Automotive and Aerospace
In the automotive sector, CBN inserts are used for manufacturing camshafts, gearing hubs, brake discs, and brake drums. These are mass-produced items, and they need to be manufactured swiftly and effectively. CBN inserts can also be put to work in the aerospace industry on landing gears and turbine shafts, where the precision is vital and expensive material should not be wasted.
Energy, Die and Moulding, Mining
Energy production involves the production of precision ground bearings and valve components. Die and mold manufacturing employs CBN inserts for hard tool steel molds. Mining needs CBN for its wear-resistant equipment and slurry pumps. HyperCBN works with each of the industries mentioned above and has numerous clients, including leading international companies.
Can grinding be replaced by CBN inserts?
In some cases, the answer is yes. This process goes under the name of hard turning. Instead of finishing a turning process and grinding the part after heat treatment, you can do hard turning of the part and cut it using CBN inserts.
The only thing you need to be careful about when using this method is that it does not imply that hard turning can replace grinding in all cases. There are many situations in which grinding will still be needed due to certain specifications concerning the smoothness of finished parts or their peculiar shapes. Therefore, you should try to carry out a test run before implementing any changes in the production process.
How to Choose CBN Inserts?
One of the most frequent reasons for being unsatisfied with CBN inserts is the incorrect selection of a grade. To avoid this, here is a three-step scheme that minimizes the occurrence of mistakes.
Step 1. Determine the type of material that will be used.
Step 2: Choose Insert Shape and Size
The choice of shape (square, triangle, or diamond) and size depends on the needs of the tool and machine. The shape influences the strength of the edge, how many corners are practical, and accessibility to the feature being machined.
Step 3: Perform a Test and Modify
Do a test cut and observe the process closely. Change the speed, feed, and depth of cut if necessary. The grade of the material should match the cutting conditions, especially whether the cut is interrupted or not. Interrupted cuts exert more pressure on the edge, thus requiring more durable grades to tackle them.
What is the Best Cutting Speed?
There is no final answer to this question, since the answer depends on the material and insert specification. In general, CBN inserts can be used at very high speeds that typically range from 100 to 400 m/min.
Step 2: Choose Insert Shape and Size
The choice of shape (square, triangle, or diamond) and size depends on the needs of the tool and machine. The shape influences the strength of the edge, how many corners are practical, and accessibility to the feature being machined.
Step 3: Perform a Test and Modify
Do a test cut and observe the process closely. Change the speed, feed, and depth of cut if necessary. The grade of the material should match the cutting conditions, especially whether the cut is interrupted or not. Interrupted cuts exert more pressure on the edge, thus requiring more durable grades to tackle them.
What is the Best Cutting Speed?
There is no final answer to this question, since the answer depends on the material and insert specification. In general, CBN inserts can be used at very high speeds that typically range from 100 to 400 m/min.
Conclusion Regarding CBN Inserts
Not all machining challenges can be solved by CBN inserts, but they do reduce the amount of time it takes to finish machining and enhance the surface of the underside of the workpiece. The secret lies in finding the ideal combination of grade and form in addition hypercbn to checking the cutting conditions before actually applying CBN. If you feel you’re ready to look for solutions,
Comments