PCD Notching Tools for Tungsten Carbide Rings/Rolls

As we all know,Tungsten Carbide Rings belong to a type Hard alloy roll,it has good abrasive resistance and high impact resistance. It has been widely used in the production of rods, wire rods, rebars, and seamless steel tubes, etc. And it usually has different grooves on the surface, we need to choose the special tools for machining these grooves.  

PCD Notching Tools can be the right choice for milling these grooves, the following is some images:

It can be divided into about 2 types:

(1) When the diameter is larger than 4mm, the size can be 4.5,5.5 or any size as customers’ requirements, we ususlly use pcd tips, please check the following image:

(2) When the diameter is smaller than 4mm, which can be about 2.5mm,2.7mm,3.2mm,we usually make it with full top face, the following image for reference:

We will also can make other types pcd notching tools as the customers’ drawings, the following is one application.

We also can offer the whole solutions for different materials rolls, such as PCD Engraving Tools, CBN Turning tools for machining Cylindrical surface.

If you have any needs on PCD Notching Tools, please feel free to contact with us halnntools@gmail.com, skype:cbn_inserts_angels

PCD Cutting Tools Classfication and Application from Halnn Superhard

Part 1 Halnn PCD Grade Materials

2. ISO PCD Indexable Insert

PCD Chipbreaker Insert

3.Non-Standard PCD Insert

4.PCD Milling Insert/PCD End Mills 

5.PCD Boring Tools 

6.PCD Drill Bits 

7.PCD Forming Insert

If you would like all above PCD Tools, please feel free to contact with us halnntools@gmail.com, whatsapp:+8618695866134,wechat:Halnntools

Hard Turning with PCBN Insert replace Grinding 

Hard Turning instead of Grinding is using turning process as the final or finishing process instead of grinding process. Turning instead of grinding has been widely used in many different industries. The following will share you some experience on hard turning insert and hard turning process advantages.

1. Hard Turning instead of Grinding improve the efficiency

Generally, the metal remove rate is about 3~4 times of grinding process, and the energy costs only about 20% of grinding process. So the efficiency will be improved obviously.

2. What roughness can the surface be achieved with hard turning instead of grinding?

In current times, the roughness with turning instead of grinding can reach Ra0.4, if with wiper insert, the insert life will extend. And Halnn BN-H10 C25 coating pcbn will extend the tool life about 1 more times than common cbn insert.

3. Dry Cutting or Wet Cutting for turning instead of grinding process

Turning instead of Grinding is formed through making the materials annealing. If with coolant, it will lower the cutting force and Increase wear, and then shorten the tool life, so it doesn’t need to add the cutting fulid. For the component which size is affected by the temperature, the customers can choose wind coolant. For some cutting process which need coolant, you can choose CBN Grade BN-H20 and BN-H10.

4. The cutting tool materials of hard turning

If it is small qty production, you can choose suitable carbide insert, If it is mass production, we can choose coating carbide insert, ceramic insert and cbn insert depending on the component hardness and working allowance.

(1) Coating Carbide Insert: Suit for the component which hardness is below HRC45, with low cutting speed.

(2) Ceramic Cutters: Suit for the component which hardness is between HRC40~55, and avoid interrupt cutting.

(3) CBN Insert: Suit for the component which hardness is above HRC45, CBN Insert also can be divided into Brazed PCBN Insert and Solid CBN Insert. And when the cutting depth is less than 0.5mm, we can choose brazing pcbn insert, when the cutting depth is between 0.5~1.5mm, this component usually belong to large scale, steel iron, mining industry, we can choose solid cbn insert. The featured CBN Grade is Halnn BN-S20 , which can be used for hardened steel and high speed steel which cutting depth is about 7mm.

Halnn already resareched a series cbn grade for hard turning from continuous, semi-interrupt to heavy interrupt turning condition, from roughing to finishing process.

CBN Content	CBN Grade	Cutting Depth	Recommend Cutting Condition
Low content	BN-S20	1-10mm	Interrupt-Continuous
	BN-H20	≤ 1mm	Semi-Interrupt
	BN-S200	≤ 1mm	Continuous
	BN-H11	≤ 1mm	Continuous
	BN-H10 C25	≤ 0.5mm	Continuous-Light Interrupt
	BN-H10	≤ 0.5mm	Continuous-Light Interrupt
	BN-H21	≤ 0.5mm	Heavy Interrupt
	BN-H21 C25	≤ 0.5mm	Heavy Interrupt

Common field which used hard turning

 

Featured CBN Insert for hard turning

1. CBN Inserts with Chipbreaker

Excellent chip breaking performance, avoid chip winding the workpiece or the tool, ensuring good surface quality and the tool life.

Different chips with same cutting condition by cbn inserts with or without chipbreaker

2. CBN Insert with Wiper

With same feed, obtain higher surface quality.

With same roughness, can be used for large feed, reduce the time on each component, improve the process efficiency.

Note: It can be used for Profile machining, suit for the CNC Lathe with high rigidity.

3. Coating CBN

The perfect combination of smooth coating and CBN base can achieve better cutting performance and improve machining accuracy and life.  

If you have any problems, please feel free to contact with us halnntools@gmail.com, Whatsapp:+8618695866134

Application of turning different materials rolls with different cbn grade

As we all know that rolls can be divided into different materials, such as cast iron rolls, chilled cast iron rolls, high Ni-Cr cast iron rolls, forged steel rolls,HSS rolls, Tungsten carbide rings,ect.

Specific for these materials rolls, Halnn make special cbn inserts grade, the following share you all the pritical case:

1. Rough machining High Ni-Cr Alloy Cast Iron Rolls

2. Semi-Finish turning chilled cast iron rolls

3. Finish turning forged steel rolls:

4. Turning Grooved Rolls with high boron steel materials

5. Machining HSS Rolls

6. Milling the grooves of the HSS Rolls

7. Milling Tunbsten Carbide rings

Common Solid CBN Inserts for Reference

How can you get the tool solutions for machining rolls from Us?

Please offer the inforamtion details as the following tablet:

If you have any problems, or would like to know more details on machining different materials rolls, please feel free to contact with us halnntools@gmail.com, Whatsapp:+8618695866134

Halnn PCBN Inserts 

Halnn PCD Inserts

Brief Introduction of Cutting Tools Material in Modern Times

Brief Introduction of Cutting Tools Material in Modern Times

Part 1 Cutting Tools Materials Performance requirement

Tool material performance requirements are mainly include strength, hardness, heat resistance, thermal conductivity and economy five areas.

First, as the tool material, high strength and wear resistance are necessary. The Cutting Tool should cut the workpiece to form the special shape. Actually, the cutting tools cut the materials depending on the Friction between the cutting tools and the workpiece. So wear resistance is also a character of cutting tools. Generally, hardness higher, better wear resistance. So the cutting tools need high hardness and excellent wear resistance.

Second, the cutting tool material need obey the vibration and shock between the cutting tools and the workpiece. So the cutting tools need high strength and good toughness.

Thirdly, the tool material needs to have good heat resistance and thermal conductivity, in which heat resistance is an important indicator of the quality of the tool material. As mentioned above, the cutting of the tool actually depends on the high-speed friction between the cutting tools and the workpiece. Friction heat,  also known as cutting heat, caused by the friction between the tool and the workpiece. So how to keep the excellent performance in high temperature is very important.

Forth, the cutting tools need excellent thermal conductivity, then the cutting tools can quickly pass the cutting heat, and reduce the heat amount and keep the tools good performance in the process.

Finally, the economy of the cutting tools. There are so many kinds of cutting tools materials. And the manufacturers also insist researching new cbn inserts materials, also the tools price will be different. So the customers should choose the right and suitable tools depending on their own conditions.

Part 2 The Classification of tool materials

Common Cutting Tools Materials include high speed steel, carbide insert, coating insert, Ceramic, Diamond and Cubic Boron Nitride.

(1)     High-speed steel is generally used as a tool for forming tooling and hole cutting tools, but it is  often used for low speed cutting because of its performance. However HSS cutting tools with high performance also are widely used after improvement.

(2)     The performance of the carbide insert will be better than HSS Tools, carbide insert are also used common process. And HSS tools also begin to be used in complex process with the improvement of the performance.

(3)     Coating Inserts are the tools of adding special coating on the HSS tools and Carbide insert, in order to improve their performance.

(4)     Diamond Tools have highest hardness in the cutting tools industry. It often is used for high precision area. It is used for machine Nonferrous metals.

(5)     And Ceramic Cutters also used in many industries, but it only can be used for low cutting speed process because of its large brittleness.

(6)     CBN Inserts. The hardness of cbn insert is only second to diamond insert. However cbn insert is used for machining ferrous metal, like hardened steel and cast iron parts.  

When you choose the cutting tools, you can choose depending on their performance and the character of the cutting tools materials itself. When you machining ferrous metals , like hardened steel and cast iron parts, cbn inserts will be your right choice. For cast iron parts, especially choosing BNK30, it will has better performance than Seco CBN.

If you would like to know something about cbn inserts, please click www.halnncbn.com, Or contact with us halnntools@gmail.com ,Or Whatsapp:+8618695866134

The whole Solutions on machining rolls with CBN Insert

The whole Solutions on machining rolls with CBN Insert

In the past, both rough machining and finish turning rolls need grinding process, while it has low efficiency and the cutting fluid will bring pollutions, and affect the health of the operator. So In modern times, hard cutting tools become featured products on hard turning hardened steel rolls and are already widely used, the processing efficiency already improved 5~10 times, which will avoid the pollutions and lower the production costs.

This article will help you analysis all the details on the whole solutions of machining rolls.

Part 1 The choice of the tool holder for machining rolls

For large scale rolls, we usually use heavy duty mill rolls, and the tool holder often is 40*40, and the holder angle can be 45 degree or radius tool holder.

For some small rolls, we usually use 25*25 and 32*32 tools holder, and the choice of the angle can be decided by the length diameter ratio, the long rolls, we can choose 90 degree and 75 degree tool holder, the short one, we can choose 45 degree or radius tool holder.

Part 2 The Rolls Materials and corresponding hardness

Part 3 CBN Insert Grades specific for different Materials Rolls and the cutting data for reference

When using BN-K1 Solid CBN Inserts machining cast iron rolls, we usually use the following models: RNMN200800, RNUN200800, RNMN150700, RNUN160800, RNUN150716, RNMN150716 .

When using BN-S20 Solid CBN Inserts machining cast steel rolls, we usually use these models cbn insert SNMN120712, SNMN120412, SNMN120408, RNMN120400.

Part 4 Application Case from our Poland customers

They begin to make market research before purchase the CNC Lathe, Halnn stand out from all competitors just because of the best service. We offer whole solutions to our customers, and offer the after-sale service.

They use carbide insert before, so they proposed using cbn inserts, however they didn’t try cbn inserts before, so Halnn help them choose the holder, hard cutting tools and the cutting data for reference, the details as follows:

Machining Materials: hilled Cast Iron and High Ni-Cr hard cast iron

Machining Type: Roughing, Finishing and Grooving

Halnn CBN Insert Grade: BN-K1

Insert Model: RNMN090400S02020，RCMX090700S10020，RCMN090700S02020

Corresponding Tool Holder: CRDNN2525M090400，CRDCN2525M090700，CRDCN2525M090700Y

Finally, they achieve good efficiency, and we have bulit long cooperation relationship. 

If you also have problems on machining rolls, please feel free to contact with us halnntools@gmail.com, Whatsapp:+8618695866134

The whole Solutions on machining rolls with CBN Insert