Solid CBN inserts from us are used for turning hard materials such as cast iron components and complex steel parts, eliminating grinding for improved quality and productivity.
These inserts are composed of cubic boron nitride micro-powder bonded together using high temperature and pressure polycrystallization and have several advantages: 1. Greater insert life expectancy.
Hardness
Solid CBN inserts are the optimal choice for turning hard metals like steel and cast iron, thanks to their superior geometry and hardness, which allow for faster cutting speeds than their brazed carbide counterparts. This allows for heavier machining without compromising quality or accuracy, whether continuous or interrupted machining, light or heavy cutting operations, making them the best option when it comes to turning such hard materials as they can often replace grinding altogether.
CBN inserts boast superior geometry and hardness, and their cutting performance allows for high feed rates and cutting speeds – increasing machine throughput while simultaneously decreasing production costs. Furthermore, their lower temperature requirement means they can be used with an array of cutting fluids; furthermore, they’re resistant to wear and corrosion – all hallmarks of excellence for any cutting tool!
CBN (powder) is composed of cubic boron nitride, the second hardest material after diamond. CBN can be used to cut both hard and soft materials, both dry and wet machining, usually combined with coolant for extra cooling and lubrication purposes. CBN inserts come in an assortment of sizes and geometries that make use of wet cutting processes – they even can feature single or multipoint cutting edges for continuous or interrupted machining!
CBN tool performance during hard turning depends on a number of variables, including workpiece material type and grade of CBN insert. Studies have revealed that insert grade plays an integral part in cutting forces and surface roughness during hard turning; however, finding an optimal angle for specific applications can be challenging; to help with this decision process, the desirability method provides optimal results curves showing all possible rates of CBN insert during hard turning operations.
Thermal Conductivity
Solid CBN inserts can dissipate heat from workpieces, thereby lowering temperatures in the cutting zone and increasing tool life while maintaining high surface finishes and cycle times. Their extended tool life means less downtime for insert changes or machine resets and, therefore can also help decrease cycle times.
The thermal conductivity of CBN tools depends on their particle concentration in their matrix. Some manufacturers treat their CBN with ceramic or metallic binders in order to optimize other properties of their sintered compact, yet this approach is less efficient than using fully non-metallic CBN inserts, which have comparable performance as Tungsten Carbide with superior hardness and superior thermal conductivity.
As well as its excellent abrasion resistance, cbn inserts offer unparalleled abrasion resistance when working with hard metals such as nodular cast iron and pearlite grey cast iron. Furthermore, their exceptional impact resistance enables them to be used across various machining applications such as turning, milling, and interrupted cutting.
CBN cutting inserts outperform cemented carbide by being twice as fast and removing 50% more material while being much less likely to work harden, an issue common with other forms of cutting inserts.
Superhard’s solid CBN inserts offer a wide variety of geometries for multiple machining requirements, from light cutting to rough turning. Both round and flat styles are available. Choose the appropriate geometry for your application, as this will have a direct impact on cutting forces and surface finish. Rounded edges produce finer surfaces, while flat ones produce coarser ones – different diameters, rake angles, and nose radiuses are available so you can select what works best. Order a kit that features various inserts suitable for a particular machining process, which will complete with a holder essential for safe operation and featuring clamping surfaces that secure them to the workpiece – make sure that it suits your machine!
Resistance to Wear
Solid CBN inserts may be more costly, but they quickly make up their cost in improved part production per shift and reduced cycle times. Furthermore, their use saves on labor associated with indexing, replacing, and cleaning inserts as well as fixing damaged tool holders; in addition, they’re more durable than their carbide counterparts, allowing longer use before needing repair or replacement; unfortunately, they don’t suit every machining application as improper use can result in poor part quality and an early wear out.
Cubic boron nitride is a tough material, second only to synthetic diamond. This makes it an excellent choice for milling hard powder metals, cast irons, and hardened steels. Due to its superior thermal stability and resistance against chemical attack as well as select wear resistance properties, it offers consistent performance over extended machining operations.
Solid CBN inserts can significantly enhance production efficiency when it comes to machining heavy workpieces by cutting more of it at one time leading to increased output and reduced costs. This is particularly effective when dealing with thick pieces such as automobile engine blocks. Furthermore, solid CBN inserts help minimize scrap production as well.
Solid CBN inserts stand out from other materials by having an exceptionally low coefficient of friction and producing minimal heat, leading to less swarf production and chip accumulation. They’re great for dry machining applications where cooling may not be available or limited, while their outstanding chip control helps reduce efforts while improving part quality.
RNGN series cubic boron nitride insert is widely utilized for rough and finishing machining of large roller and gear sets in automotive brake drum production. It can process materials up to HRC46 with ease while finishing inner/outer rings/end faces of quenched steel/hard chromium alloys.
Resistant to Deformation
Solid CBN inserts feature outstanding resistance to deformation. They can cut through hard materials like cast iron, high-temperature alloys, and hard steel without being damaged by heat generated during machining; additionally, they boast superior impact and abrasion resistance, which enables them to replace grinding in many applications.
Cubic boron nitride (CBN) is the second hardest material after synthetic diamond and features excellent thermal endurance, making it suitable for machining hard ferrous metals such as grey cast iron, nodular cast iron, ductile cast iron, and hardened steel. Solid CBN inserts also prove more resistant to chemical attacks than their carbide counterparts, which often cause corrosion on cutting surfaces when used in acid-based machining fluids.
Solid cbn inserts’ resistance to deformation makes them an excellent choice for roughing and interrupted machining processes since they reduce workpiece abrasion rates while increasing the stability of cutting edges, which is critical in producing quality results.
Carbide remains the go-to tool for hard material machining, but its popularity comes with certain limitations: high cost and limited machinability in interrupted and roughing operations. CBN may offer more economical alternatives; however, its improper application could just as likely hurt your bottom line.
CBN inserts can be utilized in many machining applications, from turning to milling. Both dry and wet machining are possible using CBNs, which come in an assortment of shapes and sizes. They have the capability of cutting through materials with a Rockwell Hardness Scale rating up to 55 and should be fed at lower feed rates than carbide inserts as increased feed rates will exert greater thrust forces upon them; care must be taken in selecting appropriate conditions when operating these inserts (Figures 6a-c show this variation of tangential force with feed rate and hardness respectively)
