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To know about the advantages and application of PCD and PCBN inserts
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By: admin
- Oct 24, 2023
- 952 Visit
I. PCD tool/PCD Inserts: Also known as polycrystalline diamond tool, diamond tool has high hardness, high compressive strength, good thermal conductivity and good wear resistance, which can achieve high processing precision and processing efficiency in high speed cutting. The above characteristics of the diamond tool are determined by the state of the diamond crystal. In a diamond crystal, four valence electrons of a carbon atom are bonded in a tetrahedral structure, and each carbon atom forms a covalent bond with four adjacent atoms, thereby forming a diamond structure, and the bonding force and directivity of the structure are strong. Thereby the diamond has an extremely high hardness.
Since the structure of polycrystalline diamond (PCD) is a fine-grained diamond sintered body of different orientation, although the bonding agent is added, the hardness and wear resistance are still lower than that of single crystal diamond. However, since the PCD sintered body behaves as isotropic, it is not easy to crack along a single cleavage plane.
According to the analysis of the application of PCD inserts in recent years, it can be seen that PCD inserts are mainly used in the following two aspects:
(1) Difficult processing of non-ferrous metal materials: When machining non-ferrous metal materials with ordinary tools, defects such as easy tool wear and often occur low processing efficiency, while PCDinserts can show good processing performance.
(2) Difficult processing of non-metal materials: PCD cutters are very suitable for processing non-metal materials such as stone, hard carbon, carbon fiber reinforced plastics (CFRP), and artificial plates. Processing these materials with PCD inserts can effectively avoid defects such as easy tool wear.
II. PCBN tools/PCBN Inserts: PCBN tools are artificial cubic boron nitride tools, which can maintain high hardness characteristics at high temperatures, mainly used for processing iron parts. Cubic boron nitride CBN was first synthesized by American General Electric (GE) under high temperature and high pressure conditions in the 1950s. Its hardness is second only to diamond and much higher than other materials, so it is Super hard material collectively referred to as diamond.
Performance characteristics of PCBN tools/PCBN Inserts:
(1) High cutting speed: When cutting hard cast iron with CBN inserts of Mintek tools, higher cutting speed can be used. When Vc=60m/min, after cutting for 160min, the flank face only wears 0.16mm. The cutting speed of the YG6X carbide tool is only 6.6m/min, which is only 1/9 of that of the CBN inserts of Mintek tools.
(2) High durability: HRC55 chilled cast iron is machined with a CBN inserts round insert with a cutting capacity of Vc=40m/min and f=0.16mm/r. The tool durability is 500min, while the tool is processed with ceramic inserts. Durability is only 5min. CBN inserts are 100 times more durable than ceramic inserts.
(3) Processing accuracy and surface quality is good: the surface of the HRC50 is sprayed with a hard-hardened cast iron roll with a carbide inserts. When Vc=20m/min, ap=0.3mm, f=0.22mm/r, the roundness error is up to 0.5mm. The surface roughness Ra is 12.5 μm. When the CBN inserts is used for turning, the cutting speed is improved, the roundness error is small, and the surface roughness Ra is less than 0.8 μm.
(4) High metal removal rate: The cubic boron nitride solid polycrystalline insert developed by Mintek tools began to be used in heavy-duty roughing. The cubic boron nitride inserts began to be applied to large feed, and deep rough processing. The cutting rate is higher than that of cemented carbide inserts. For example, cutting a chilled cast iron roll with a cubic boron nitride CBN inserts can achieve a very high metal removal rate.
(5) Can replace grinding: ASH centrifugal mud pump is made of extremely wear-resistant nickel-chromium white iron. This material is extremely difficult to cut. It was previously thought that only grinding can be used, but the high temperature during grinding causes hot cracks in the workpiece. It is now possible to use a cubic boron nitride CBN inserts for grinding. This inserts has a high flexural strength and can withstand impact loads.
Application examples of PCBN tools/PCBN inserts:
Because PCBN has high hardness and wear resistance, it is chemically inert that does not react with iron group metals at high temperatures, so it is mainly used for cutting of high hardness materials and difficult-to-machine materials, such as hardened steel and high alloy wear resistance. Cutting of difficult-to-machine materials such as cast iron, high-temperature alloys, high-speed steel, surface spray welding materials, and sintered metal materials.
(1) Machining hardened steel and high hard cast iron can achieve the effect of grinding by turning. Since the cutting depth is more than ten times larger than the grinding depth, the machining efficiency is high and the surface does not burn. For example, when the variable speed sliding gear (20CrMnTi, hardness HRC58-62) is machined on the vehicle, the cutting efficiency is increased by more than 4 times than that of the original grinding.
(2) Processing high-alloy (containing tungsten or high-chromium 18%) wear-resistant cast iron, the cutting speed is increased by more than 10 times and the cutting efficiency is increased by more than 4 times than that of hard alloy and carbide inserts.
(3) For processing high-cobalt-chromium-molybdenum corrosion-resistant heat-resistant alloys, the cutting speed of PCBN inserts is 160m / min, which is 8 times that of hard alloy and carbide inserts.
(4) When processing thermal spray (spray welding) materials, the surface spray welding parts can not be ground, but the cutting efficiency of carbide inserts is extremely low. Switching to PCBN inserts can improve processing efficiency and save processing costs by more than 50%. PCBN inserts can also be used for some precision cutting of non-ferrous metals and cutting of sintered metals some times if the hardness could up to more than HRC50.
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