2 PCBN is the ideal tool material for dry cutting process
Due to economic and environmental reasons, in recent years, dry cutting processing has become a key research topic in the field of mechanical manufacturing. The dry cutting process has been well applied in western industrialized countries. Compared with wet cutting, dry cutting can greatly improve productivity. The mechanism is that when the cutting speed is high, the heat generated is concentrated in the front of the tool, so that the material near the cutting zone reaches a red hot state, and the yield strength decreases, which is improved. The effect of cutting efficiency. The premise of using the dry cutting process is that at higher cutting temperatures, the strength of the material to be cut is significantly reduced, making it easy to cut, and the strength of the tool material should have better red hardness and thermal stability under the same conditions. Have better wear resistance and adhesion resistance. Tool materials suitable for dry cutting process are ceramics, cermets, coated cemented carbides and PCBN tool materials, but in terms of red hardness and thermal stability, PCBN materials are the most suitable tool materials for dry cutting processes.
3 PCBN tools are suitable for automated machining and difficult machining of materials
(1) PCBN tools have high hardness and wear resistance, can process high-precision parts for a long time at high cutting speeds (small size dispersion), greatly reducing the time required for tool change and tool wear compensation. Suitable for CNC Machine tools and processing equipment with a high degree of automation.
(2) PCBN tools can successfully implement the hard finishing process, which can replace the grinding process in addition to the economic and ecological advantages of using cooling lubricants and related materials. In the application of difficult-to-machine materials, PCBN tools also show excellent performance, such as surface spray-welding (coating) materials, machining with other materials, tool life is extremely low, and can not be processed by grinding, and PCBN is The only suitable tool material.
(3) High-alloy wear-resistant cast iron used in petroleum and power station equipment. The cutting efficiency of cemented carbide tools is more than 4 times higher than that of PCBN tools. The cost of single-piece tools is reduced to 1/5. In addition, in hard alloys. PCBN tools also show good cutting performance in terms of cutting of hot-pressed materials. PCBN tools can be used for precision hardened steel and high speed milling of grey and hard cast iron. The surface roughness Ra of the hardened steel after finishing the car can reach 0.3~0.6μm, and the dimensional accuracy can be controlled within 0.013mm. PCBN tools can also be used to process superalloys, hard alloys, engineered ceramics and other difficult-to-machine materials.
(4) In terms of cutting chilled cast iron, the durability and processing efficiency of PCBN is far better than that of cemented carbide tools. Because diamond knives react with ferrous metals, they cannot be used to cut steel or iron. In industrial engineering and machinery manufacturing, ferrous metals, especially steel and iron, are the largest, so PCBN has a unique advantage in this respect.
(5) PCBN tools can process black metal materials that cannot be processed by diamond tools, and are especially suitable for the use of numerical control equipment and automated production lines. PCBN tools have high wear resistance, and their service life is much higher than that of hard alloys. They can process most high-hardness materials. In many cases, they can be replaced by car, boring, milling, etc. High precision and good surface quality, and greatly improve production efficiency. Foreign PCBN tools have been widely used to process hardened steel, high hardness cast iron and anti-wear parts, and bring huge economic benefits. As the hardness and wear resistance requirements of mechanical parts are further improved, the use of PCBN tools will be more extensive.
PCBN tool promotion and application status
(1) Early PCBN tools were hard but lacked sufficient toughness, so the range of use of PCBN tools was limited. PCBN tools are not suitable for quenched and tempered steels with medium hardness and normal hardness of normal hardness steel. In practical applications, medium and low hard steels are used a lot. Therefore, people use more cemented carbide tools, PCBN tools. Mainly used for finishing and semi-finishing of hard materials.
(2) PCBN tools have been developed in China for nearly 30 years, but their use ratio has always been limited. The share of all tools is insignificant compared to high-speed steel and hard alloy. The main reason is that people have insufficient understanding of PCBN tools; PCBN is expensive to manufacture and expensive; the toughness of the blade is constrained by processing conditions. .
(3) At present, the domestic users use PCBN turning tools. These tools have achieved good results in the continuous turning of chilled cast iron, hardened steel, and other difficult-to-machine parts, in order to promote the use of PCBN. The tool laid a good foundation. PCBN tools are mainly used in the domestic market: automotive, petroleum exploration, mining companies, related steel pipe plants, power plant equipment and steam turbine plants, and other types of machinery plants.
(4) The number of grinding machines specially used for bearing production in China has exceeded 4,000, and the bearing export has always been in a good situation, and the supply is in short supply. At present, the processing of inner and outer rings of domestic bearings is mainly processed by ceramic tools, and the PCBN tools have not been effectively developed. If the PCBN tools are used for hard cutting of bearing steel, the economic benefits will be considerable.
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