As an indispensable tool in the processing industry, cutting tools play an indispensable role in the industry. When processing workpieces, CBN blades rely on their super hardness and stable performance and are mainly used for multi-processing in the industry.
CBN cutting tools are synthesized using artificial methods, using a small amount of CBN powder and a small amount of binding agent under high temperature and high pressure conditions. Its hardness is second only to diamond and much higher than other materials, so it is combined with diamond cutting tools.
CBN cutting tools have extremely high hardness, thermal stability and chemical inertness. Its thermal stability is much higher than that of diamond, and it has strong chemical stability among iron elements. The use of CBN tools has made a great contribution to metal processing, thus causing revolutionary changes in the cutting process, which is the second leap in cutting technology.
2.What types of materials can CBS tools process?
According to statistics, CBN tools are often used to cut ferrous metals, mainly including high-hardness cast iron/cast steel/forged steel, quenched steel, ordinary gray cast iron, powder metallurgy and other difficult-to-machine materials (steel above HRC45).
(1) High hardness cast iron/cast steel: Materials such as high chromium cast iron, alloy cast iron, nickel hard cast iron, white cast iron, high manganese steel, high speed steel, etc. can be processed, for example, rollers, slurry pump casings, impellers, Guard plates, liners, etc. are all typical parts. This kind of workpiece is mainly processed by solid polycrystalline CBN blades, which can cut the blank with a large margin, improve production efficiency, and reduce the total production cost. For example, the Valin superhard BN-K1 grade rough turning roll blank has a large margin of cutting depth. Not only does it not chip, it can also withstand the impact of surface casting defects to ensure surface quality.
(2) Quenched steel: Parts such as quenched gears/gear shafts, bearings, molds, synchronizers, ball cage universal joints, quenched rollers and other parts are typical quenched parts with a hardness of about HRC60. CBN blades can easily solve them and ensure high Surface smoothness, such as the Valin super-hard BN-H21 hardened wheel for strong interrupted cutting, not only does it not collapse, but it can also achieve a higher surface finish.
(3) Ordinary gray iron: such as engine block/cylinder head, brake disc, brake drum, pulley, clutch pressure plate, etc., are all gray iron materials. Using CBN tools to replace carbide inserts for high-speed cutting, the cutting speed is several times faster than carbide tools. And on the premise of ensuring high surface quality, the tool life is 10-20 times that of carbide inserts. For example, Valin’s ultra-hard BN-K20 precision-machined brake disc is 50% faster than the coating brake process.
(4) Powder metallurgy: Due to its porous structure, the hardness of part particles is as high as HRC60. Using CBN blades can easily cause edge fatigue and micro chipping. The use of CBN blades can effectively improve production efficiency and ensure the tool life. The invention of Valin Super Hard BN-K10 brand processing powder metallurgy pulleys not only reduce the number of tool passes, improve production efficiency, but also have the same service life as other CBN blades, reducing production costs.
3. Application manifestations of CBN cutting tools:
(1) High-speed cutting: mainly reflected in the field of ordinary gray cast iron. Due to the rising prices of gray cast iron raw materials, competition among enterprises has become increasingly fierce. The linear speed when processing gray iron with carbide blades must not exceed 350m/min, otherwise severe wear will occur. The linear speed of gray iron processing with CBN tools can reach 1500m/min (regardless of machine tool rigidity), and it can ensure high wear resistance and high surface quality when processing workpieces.
(2) Heavy cutting: mainly in the fields of high-hardness cast iron/cast steel, such as rolls, pump body materials are used on large equipment, and the blank processing margin is large, which requires cutting tools with both wear resistance and impact resistance, and CBN blades The cutting depth can reach 10mm at one time.
(3) Dry cutting: No matter what type of material is processed, CBN blades are processed using dry cutting. CBN tools are red and hard at high temperatures and can withstand normal cutting under high temperature conditions of 1200°C, ensuring excellent durability. And it reduces unnecessary costs caused by using cutting fluid to process workpieces, ensuring a good production environment.
4. Regarding the structural form of CBN blades:
According to the structure, it is divided into welded CBN tools and integrated CBN tools:
(2) The entire polycrystalline integrated CBN tool is made of CBN material throughout the tool block. There is no hole in the middle. It requires the cooperation of a professional tool holder and is mainly used for rough machining.
5.Wide applications of CBN tools:
(1) High-speed cutting: mainly reflected in the field of ordinary gray cast iron. Due to the rising prices of gray cast iron raw materials, competition among enterprises has become increasingly fierce. The linear speed when processing gray iron with carbide blades must not exceed 350m/min, otherwise severe wear will occur. The linear speed of gray iron processing with CBN tools can reach 1500m/min (regardless of machine tool rigidity), and it can ensure high wear resistance and high surface quality when processing workpieces.
(2) Heavy cutting: mainly in the fields of high-hardness cast iron/cast steel, such as rolls, pump body materials are used on large equipment, and the blank processing margin is large, which requires cutting tools with both wear resistance and impact resistance, and CBN blades The cutting depth can reach 10mm at one time.
6.What are the specific application areas of CBN blades?
(1). Automotive Industry:
In the demanding automotive industry, where parts undergo extensive wear and stress, CBN blades are indispensable. These blades are meticulously utilized in cutting and grinding hardened steel components, engine parts, and transmission gears. Their exceptional hardness and wear resistance ensure the longevity and reliability of automotive parts. By maintaining sharp edges even in high-stress conditions, CBN blades contribute significantly to the industry’s high standards of quality. From crankshafts to camshafts, these blades play a pivotal role in crafting the robust components that power vehicles, aligning seamlessly with the automotive sector’s need for precision and durability.
(2). Aerospace Manufacturing:
In the aerospace sector, precision reaches a paramount level, and CBN blades stand tall to meet the challenge. Their applications extend to machining critical components such as turbine blades, landing gear parts, and aircraft engine components. The role of CBN blades in achieving precise dimensions and immaculate surface finishes is unparalleled. These components demand an extraordinary level of accuracy, and CBN blades, with their ability to maintain sharp edges and consistency in performance, ensure that aerospace manufacturers meet the stringent requirements of the industry. From turbine discs to intricate engine casings, CBN blades are the linchpin in the aerospace manufacturing process, ensuring the highest level of precision and safety in the skies.
(3). Tool and Die Making industry:
In the intricate world of tool and die making, where precision is non-negotiable, CBN blades find a definitive purpose. These blades are expertly employed in cutting and shaping hardened metals to create molds, dies, and precision tools. What sets CBN blades apart is their ability to maintain razor-sharp edges, contributing to the creation of highly detailed and accurate molds. Whether it’s intricate patterns for industrial components or specialized tools for specific applications, CBN blades are the craftsmen’s choice. They ensure the intricate details in molds and dies are replicated with utmost precision, underpinning the quality of countless industrial products.
(4). Bearing Manufacturing:
The manufacturing of high-precision bearings requires a tool that matches the industry’s exacting standards, and CBN blades fit the bill perfectly. These blades are instrumental in grinding hardened steel and ceramic materials, essential for high-precision bearings used in automotive, industrial, and aerospace applications. The exceptional wear resistance and consistency in performance exhibited by CBN blades are crucial in achieving the tight tolerances demanded in bearing manufacturing. From ball bearings in automotive wheels to intricate roller bearings in industrial machinery, CBN blades ensure the smooth rotation and reliability of vital mechanical components.
(5). Medical Device Manufacturing, Woodworking, and Composite Materials:
CBN blades are not confined to metal; they venture into the realm of shaping hard materials such as titanium, stainless steel, laminates, particleboards, and fiberglass-reinforced composites. In medical device manufacturing, where precision saves lives, CBN blades craft intricate and high-precision components for implants, surgical instruments, and medical devices. In woodworking, CBN blades bring precision to crafting fine furniture, ensuring clean cuts in hardwoods and laminates. Moreover, these blades find a home in shaping composite materials, from aerospace-grade composites to everyday products, ensuring a blend of strength and precision. CBN blades, with their longevity and consistent quality, contribute significantly to the efficiency and precision of manufacturing processes in these diverse fields, where materials vary but the demand for perfection remains constant.
In every application area, CBN blades stand as testaments to precision, durability, and innovation. Their ability to shape the future of manufacturing, whether in the automotive, aerospace, tool and die making, bearing manufacturing, medical device, woodworking, or composite material industries, reinforces their significance as the cornerstone of modern precision machining.
