Compared Ceramic insert and Halnn CBN insert

When process the machinery,inserts has been always referred to as "industrial manufacturing teeth," while cut performance of the cutting tool material determine the efficiency of its production,and the tools material also play an important role in production costs and processing quality, therefore, the proper selection of cutting tools material is so crucial, ceramic tool has a good advantage in excellent heat resistance, wear resistance and chemical stability,  the main raw material of the ceramic tools are Si and Al ,and there are a lots the two elements in the crust, it is said that they are inexhaustible. Therefore the new type ceramic tool has a good prospects.

Part 1 The types of ceramic tool
The development of ceramic tool materials focused on improving the ceramic materials of the traditional tools performance, grain refinement,composite components,the use of  coatings,improve the sintering process and development of new products, etc.

In order to obtain high temperature resistance, abrasion resistance and anti-excellent chipping performance which can match the needs
of highspeed precision machining. Halnn superhard Institute divide the material of ceramic tools into three categories:alumina, 

Cubicboron nitride (CBN tools) .In metal field, alumina ceramic inserts and silicon nitride ceramic tools are both called ceramic tools; while in inorganic non-metallic materials science, cubic boron nitride material attributed to the ceramic ma-terial categories. 

The following are the characters of the three types of ceramics.

(1) Alumina (Al₂O₃) based ceramics: carbide ceramics add Ni, Co, W, etc. as a binder metal, can increase the bonding strengthof aluminum and carbide. With good wear resistance, heat resistance, and good high temperature on chemical stability,hardly occur mutual diffusion or chemical reaction with iron element , so alumina ceramics was used most widely, it suitable for steel, cast iron and highspeed machining alloys;as the improvement of the thermalshock performance it can also be used for milling or planing under intermittent cutting conditions, but it should not be used for machining aluminum, titanium and tantalum alloys, otherwise prone to chemical wear.

(2) Silicon nitride (Si₃N₄) based ceramic tool: adding an appropriate amount of metal carbide , metal and composite enh-ancer base on the silicon nitride matrix, and use the composite strengthening effect (also known as the dispersion strengthening effect) produced. Characters include: good high hardness, wear resistance, heat resistance, oxidation resistance. silicon nitride
will has a smaller chemical reaction with carbon and metal element, friction factor is also little. Suitable for fine cutting, semi-cutting , fine milling or semi-intensive milling.

(3) Boron nitride ceramics (cubic boron nitride cutting tool): High hardness, wear resistance, heat resistance, good thermal stability, and also have good thermal conductivity, lower coefficient of friction, small linear expansion coefficient.Such as cubic boron nitride BN-S20 grade tool for roughing hardened steel which from Halnn superhard company, BN-H10 Grade for high speed finishing the hardened steel, BN-K1 grade processing the high hardness cast iron, BN-S30 grade high-speed cutting the gray cast iron ,they are all can get a better economic returns than ceramic inserts.

Part 2 the characteristics of ceramic cutting tools

Characteristics: 

(1) good wear resistance;

(2) high temperature resistance, good red hardness; 

(3) the tools life was several times higher than traditional tools, reducing the tools changes times when Processing, guarantee the machined workpiece small taper and high-precision; 

(4) not only can roughing and finishing the high hardness material , but also for milling, planing, intermittent cutting and rough pulling force shortage roughing impact such a large processing; 

(5) the friction is small when cutting metal with ceramic inserts,not easily adhered to the cutting blade, not easy BUE, and also can perform high-speed cutting.

Ceramic inserts compared with the carbide inserts: ceramic blade can stand high temperature about 2000 ℃, but cemented carbide will be soften   at 800 ℃; ceramic tool was more hightemperature chemical stability, high speed cutting, but its disadvantantage is that the ceramic blade strength and toughness is very low, easily broken. Then we research the boron nitride ceramic (also known as cubic boron nitride(CBN) cutting tools), mainly used for turning, milling, boring superhard materials. Cubic boron nitride cutting tool is much higher than the hardness of the ceramic tools, due to the high hardness, we call that superhard material with diamond together, often used to process a material which hardness harder than HRC48, it has excellent high-temperature hardness - up to 2000 ℃, though it was brittle than carbide inserts, impact strength and resistance to crushing performance has improved significantly compared with alumina ceramic inserts. Moreover, some special cubic boron nitride cutting tools (for example: BN-K1 grades and BN S20 grade from Halnn superhard company)  canstand a large  margin roughing chip load, also can stand the impact of interrupted during cutting and finishing time wear and cutting heat, these features says we can roughing har-dened  tool steel  and high hardness cast iron with CBN inserts.

We will introduce the application scope of Halnn superhard material companies CBN inserts .

Part 3 Halnn superhard cubic boron nitride cutting tools applications

Halnn superhard company was called Henan Institute of superhard materials before,was professional for manufacturing cubic boron nitride cutting tools and other superhard materials products.Being the first one research inserts production match gray cast iron, all kinds of cast iron / steel, hardened steel tools and other materials. Especially was perfect in intermittent cutting hardened steel, high chromium cast iron processing and many other areas, leading the worldclass level, in academia Halnn superhard tools enjoyed a high reputation as a pioneer in the localization of superhard cutting tool, hard materials processing and high-speed machining the most well-known tool brands.Halnn brand CBN tool used the non-metallic ceramic as a adhesive successfully, and further balance the CBN tool brittle and ductile, is one of the advantagesof this tool brand. 

As a machine folder indexable CNC blade structure, as shown in the table blade style, cubicboron nitride inserts divide into welded CBN inserts and solid PCBN inserts, welded insertsCBN usually apply for finishing , cut at about 0.3mm and less, while the overall sintered CBN inserts can cutting difficult materials in large margin , particularly was perfect in strong interrupted cutting machining in tool industry,Halnn superhard material as a national brand was known all over the world. The following is welded CBN inserts and integral CBN inserts
application table:

The grade and application of Halnn’s welded CBN inserts

 The grade and application of Halnn’s integral CBN inserts

Part 4 Conclusion

At present, the ceramic cutting tools developed rapidly, the level of research and development equal the international.Through the study of ceramic tool ceramic tool material components, manufacturing process and materials design can improve the toughness and impact resistance greatly based on high hardness, high wear resistance and red hardness, prepared in line with modern cutting techniques using suitable materials requirements. It is the realization of an efficient turn instead of grinding "hard processing technology" and "dry cutting technology", improve part surface quality. Achieve dry cutting, the control of environmental pollution and reduce manufacturing costs have broad application prospects.

More information ,please check http://www.halnntools.com/news/focus/128.html,Or contact with us halnntools@gmail.com,skype:cbn_inserts_angels,whatsapp:+8618695866134 

Halnn CBN Cutting tools processing hardened steel well

 As the Hardened steel has a good performance, it  used in various mechanical industries widely.We all know hardened steel was a steel workpiece which been heat treated,the hardness was usually HRC45 or higher ,and its difficult to process, especially
in roughing , interrupted cutting or when the grooving, with a large margin.So we need choose a tools which  with a higher intens-ity and better impact resistance.

This article mainly introduce the performance characteristics of the harden steel and how to choose the right materi-als of the cutting tool to cut hardened steel.

Part 1 The performance characteristics of cutting hardened steel and the simple processing of cutting hardened steel

1.    the features when cutting hardened steel when

(1)The harden steel has a higher hardness and strength after heat treatment,
almost no plastic; 

(2) hardened steel has a huge cutting power and high temperature when cutting , this easily lead to edge chip-ping or severe abrasion; (3) not easy to BUE; (4) lower thermal conductivity.

2. the process of cutting hardened steel: cutting - casting (or forged) - normalizing (or annealing) - roughing - Heat treatment - Grinding. These are the beginning of the process,the workpiece is difficult to machine due to the  higher hardness after heat tre-atment , grinding can only be the final step of cutting hardened steel, but the grinding efficiency is very low, with production gra-dually hardened steel, grinding affect the overall processing efficiency. Therefore, with the continuous research of tool industry practice, ultimately has developed a hardened steel cutting tools,lathe instead of grinding , they are :carbide cutting tools, coa-ted carbide tools, ceramic cutting tools and cubic boron nitride(CBN) tool. Divided by the hardness: Carbide Tool <Coated Carbide Tool <ceramic tool <cubic boron nitride(CBN) cutting tool; toughness: Ceramic Tool <Carbide Tool <Coated Carbide
Tool <cubic nitride boron tool, You can get this Specific analysis as follows:

Part 2 The tools for cutting hardened steel

Carbide Tool: Carbide Tool is the latest developed one more than other three tools, and is still mainstream products in the tool industry, but not for cutting hardened steel because of the hardness of the carbide cutting tools body is between HRC71 to 76, and the hardness of hardened steel after heat treatment was general about HRC45 or more, the tool does not wear well in the process, if you didn’t usually cut hardened steel with it, without considering the overall processing efficiency and tool costs in the case, you can select the appropriate carbide cutting tools.
Coated carbide tools: coat a layer of wear-resistant material about 2 ~ 18μm on the carbidecutting tools which has a good toughness,It has a better strength, hardness and wear resistance than uncoated carbide tools . But there are not enough good, mainly due tothe wear layer of surface coating is too thin, after the wear layer was run out, its performancewas just like the carbide cutting tools without wear coat. But still can turning the workpiece which hardness is less than HRC45 workpiece at low speed.

Ceramic tool: we all know the ceramic tools had a better hardness, strength, wear resistance than the carbide tools and coated carbide tools, but the only biggest disadvantage was its bad brittleness, ceramic tool using normal , lathe speed was 2 to 5 times than carbide tools, especially suitable for using high hardness materials processing, finishing and high-speed machining. Can machine the hardened steel workpiece which hardness was betweenHRC45 to 55, but we don’t suggest you choose the ceramic tools when intermittent cutting or margin excessive, ceramic knives met this casewill chip intermittently, and it only can turning hardened steel with a small feed cutting or knife depth.

Cubic boron nitride(CBN) tools: The resistance and hardness of CBN tools is just next to the diamonds, has a excellent high-temperature hardness.CBN tools has a  better impact  strength and resistance crushing performance compared with ceramic tools.It is widely used for cutting hardened steel which has a hardness more than HRC45, it has a new better cutting speed compared with carbide cutting tools.Especially the non metallic adhesiveIn cubic boronnitride cutting tools researched by Halnn superhard tools company, Solved the problem which traditional cubic boron nitride cutting tools just can finishing machine the hardened steel .

Since Halnn superhard company founded, keep researching ,offering high-quality, high-performance tool products. With long-term trying,cutting-edge technology and  development  capabilities, Being the first one who raise "CBN overall polycrystalline Blade"concept. And Halnn Superhard tools got a high reputation in the industry.

Halnn superhard company developed the different grades tools according to the different hardened steel.The Halnns tools not only has a high effectiveness but also with a low cost. We suggest the followed parameters and the corresponding cutting
grade tool as the table:

What we can get from the above table: The BN-S20 grade tools researched by Halnn superhard company can machine both rough and finishing, as the BN-S20 brands belong to non-metallic adhesive overall PCBN cutting tool (as Picture 1 ), it has a higher hardness, better wear resistance and impact resistance, also can be interrupted cuts and a large margin of cutting hardened steel. there are a lot of brands for the finishing process , they mainly were the welding cubic boron nitride(CBN) cutting tool (as Picture 2), the depth of
cut is better controlled in less than 0.5mm, the BN-S200 grades belong to the monolithicCBN tools , but mainly for the finishing process.
Here's a brief introduction to the actual cases about cutting parameters of Halnn superhard cubic boron nitride cutting tool
for cutting hardened steel.

Part 3 The case
1.Halnn superhard cubic boron nitride cutting tools BN-H10 grade for hardened steel gear  cutting parameters:ap=0.2mm,Fr=0.1mm/r,Vc=180m/ min.

2.Halnn superhard cubic boron nitride cutting tools BN-H20 grade hardened steel synchronizer  cutting parameters:ap=0.15mm,Fr= 0.1mm / r,Vc=170m/min.

3.Halnn superhard cubic boron nitride cutting tools BN-S20 grade hardened  steel gear (strong interrupted cutting) cutting parameters: ap = 2.5mm, Fr = 0.12mm / r, Vc = 90m / min.

4.Cutting parameter of Halnn superhard cubic boron nitride cutting tools BN-S200 grade  hardened steel slewing ring bearings: ap = 0.5mm, Fr = 0.45mm / r, Vc = 110m /min.

Part 4 Summary

Recently, with the development of modern technology, more and more hardened steel difficult to machine appear on the processing site, machinery manufacturers has been looking for efficient cutting tools material for hardened steel in order to get a good piece size and hardness of the workpiece.which for the tool industry, as long as the constant times, developed
a high hardness, high-quality, high-efficiency tools material, will be able to obtain benefits for the company,at the same time also can promote state's development of machinery manufacturing industry.

More information ,please check our web:http://www.halnntools.com/news/case/127.html ,feel free to contact with us halnntools@gmail.com ,Or skype:cbn_inserts_angels

Hard turning hardened steel after heat treating used CBN insert Grade

Part 1 The problems of CBN insert hard turning hardened steel

1.Hardened steel problems: High hardness; interrupted turning process; Large deformation;

2.Cutting Tools difficulties: Carbide insert has low hardness; Ceramic insert has large brittleness; Traditional cbn insert will be easily chipping.

Part 2 The solutions of Halnn CBN insert hard turning hardened steel after heat treating

Specific to the current problems on hard turning hardened steel after heat treating, Halnn researched special cbn insert ,and offer the effective solutions as follows:

CBN insert grade	Machining Process	Advantages	Application industry	Insert Picture
BN-H10	Finishing	Suit for finishing with high speed, balance the wear resistance and Collapse resistance	Bearing , gear, gear shaft, constant speed coupling, pearlite ductile cast iron
BN-H21	Finishing	The tips has excellent strength and performance well in interrupted turning conditions	Gear and gear shaft ,mold steel
BN-H11	Finishing	It has more flexible with the cbn insert clamping way, higher machining accuracy, more than one tip	Bearing, Gear, Gear shaft, Constant speed coupling, hardened abrasive
BN-H20	Finishing	it has a good wear resistance and crack resistance when hard turning hardened steel	Brake disc, brake drum, cast iron parts, chilled steel gear
BN-S20	Finishing & Roughing	It has a good chipping resistance and fracture-resistant in a high temperature	Hardened steel rolls, ball screw, wind power bearing ,high speed steel rolls
BN-S200	Finishing & Semi-finishing	It has a better wear resistance when hard turning hardened steel and heat resistance alloy	Slewing bearing, forged chilled rolls ,sintered tungsten carbide

More information ,please check http://www.halnntools.com/pro/

Any questions on hard turning hardened steel or quenched steel ,you can feel free contact with us halnntools@gmail.com ,skype:cbn_inserts_angels .

Finish turning hardened steel part Gears after heat treatment used CBN insert Grade

In order to suit for high speed and strong strength working conditions, the manufacturers will choose quenching after rough machining the gears to obtain high hardness. The hardness of the gear after heat treatment usually is about HRC60,and some gears has interrupted turning condition, so it will be difficult to machining, so it is very important to choose the cutting tools materials. Only choosing the most suitable cutting tools and the cutting parameters, it will obtain excellent working efficiency and the gear precision .

If choosing the traditional cutting tools (such as carbide insert and ceramic insert) hard turning gear, it will often appear chipping phenomenon, which will affect the working efficiency and increase the insert costs.

Halnn superhard, as one professional manufacturer of cbn insert, continuous researching new type cbn insert with high performance and high quality, high efficiency. And Halnn cbn insert mainly used field as follows: high hardness cast iron, hardened steel ,gray cast iron and powder metallurgy industry.

Specific to finish turning gear process, Halnn superhard researched non-metal adhesive cbn insert to hard turning gear.

Compared with traditional insert, When Halnn cbn insert hard turning gear, it will not chipping, and the roughness will arrive Ra0.4, improving the working efficiency, lower the processing costs, and is the most suitable cbn insert for hard turning gear process with HRC60.

Specific to finish turning hardened steel part Gears process, Halnn researched 2 grades cbn insert :

(1) BN-H11 grade cbn insert, finish turning gear with high speed and high precision, such as machining gear wheel and gear shaft ,ect. BN-H11 cbn insert mainly suit for continuous processing with high efficiency and low costs.

(2) BN-H20 cbn insert , finish hard turning gear end surface(with hole).BN-H20 cbn insert has high precision ,and suit for semi-interrupted turning process.

Application Case 1

Halnn BN-H20 CBN insert interrupted turning gear

Work piece Materials:20CrMoTi

Processing Part: inner bore (semi-interrupted machining)

Insert Grade:HRC58~62

Cutting Parameters: N=1180r/min ,Feed Rate: Fr=0.1mm/r ,depth of cut ap=0.15mm,

Working Efficiency: When semi-interrupted turning gear inner bore ,the cutting tools have excellent impact resistance and wear resistance, it will not have chipping phenomenon, ang the precision will arrive Ra1.6~0.8.

Application Case 2

Halnn CBN insert finish turning gear end surface

The work piece diameter:167mm

The work piece materials :20CrMnTi

The work piece hardness:HRC57~61(after quenching)

Machining Part: Gear end surface

Cutting Type: interrupted Cutting

Insert Grade: WNGA080404

Cutting Parameters: Cutting Speed Vc=157m/min,the depth of cuts ap=0.3mm, Feed Rate: Fr=0.1mm/r

Working efficiency: One cutting edge can machining about 200 piece work piece ,and will not have chipping phenomenon.

Halnn superhard always devote to researching new type cbn insert to satisfy the customers’ requirements.

More related to gear wheel ,please check http://www.halnntools.com/news/know/197.html,Or contact with us halnntools@gmail.com ,skype:cbn_inserts_angels

BN H10 CBN insert hard turning hardened steel

Turning inserts for hard turning hardened steel

Part 1 Coated carbide material inserts

Coated carbide inserts is coating on good toughness carbide cutting tools by the thickness of 2-18µm.It lowers the heat conduction efficiency after coating and abate the hot action of cutting tool substrate, Coating can effectively improve the cutting process of friction and adhesion effect, reducing the heat caused during cutting. Coated carbide cutting tools has a better strength, hardness and wear resistance than the carbide cutting tools. Low-cost coated carbide inserts can realize low speed when turning the work piece which hardness was under HRC45.

Part 2 Ceramic material inserts

The turning speed of ceramic inserts is 3-5 times faster than carbide inserts with normal machining. Ceramic inserts is especially suit for processing hardness materials with high speed, finishing process and high speed process. We can choose ceramic inserts to finish turning hardened steel with hardness HRC45~HRC55,and had better avoid interrupted turning.

Part 3 CBN(Cubic Boron Nitride) material inserts

The CBN hardness and wear resistance are second only to diamond, has a wonderful hot hardness, and also has a better impact strength and breakage resistance compared with ceramic inserts. It is widely used for turning the Hardened steel (more than 50 HRC), pearlite gray cast iron and chilled cast iron and high temperature alloy. CBN inserts has a much higher cutting speed than carbide inserts.

PCBN inserts with high content CBN is harder, better wear resistance, better compressive impact and toughness ,but its defect is low thermo stability and chemical inertness, which is suitable for machining heat resistant alloy, cast iron and iron series sintered metal. CBN particle content in the composite PCBN cutting tools is low, using the ceramic as binder, which hardness is low, but make up for the before one materials defect which low thermal stability, chemical inertness, PCBN used for machining hardened steel.

Part 4 Summarize

We can choose both ceramic and CBN inserts when machining hardened steel, you can analyze the producing cost and machining quality so that which one is more economical. PCBN material cutting tools has a better performance than Al2O3 ceramic inserts, and the latter has a better thermal chemical stability. But PCBN inserts has a better toughness. Generally, ceramic inserts will be better choice when machining the hardened steel work piece with hardness less than HRC50 with thin cutting depth and small feed rate. while PCBN tool is suitable for machining the work piece with hardness above 50 HRC, especially for automation and high precision machining .In addition , with the same blade wear, PCBN cutting tools has a better stable residual stress than ceramic inserts after they stand the same wear of the cutting tools flank cutting surface. In addition, ceramic inserts should avoid using for roughing and semi-finishing, Halnn company developed integral CBN inserts can be suitable for interrupted turning , hard roughing the hardened steel overloading.

CBN inserts grade turning high hardness steel after heat treating

High hardness steel

1.Hardened bearing steel

2.Carburizing steel

3.Tool steel after heat treatment

4.High temperature alloy

5.Powder metallurgy

.
Halnn superhard CBN insert used for machining high hardness steel parts

When turning high hardness alloy steel, because it will have high hardness, it will produce a large turning quantity heat, have a big cutting force; and will cause hard turning inserts wear rapidly, or the insert tips chipping. Halnn superhard will give you some advice on the cutting parameter with the experience of turning high hardness alloy steel.
The insert material grade and characteristic of Halnn superhard insert turn high hardness alloy steel

BN-S20 CBN insert: Rough machining and finish turning high hardness alloy steel with HRC45~HRC79,such as: High hardness W18Cr4V high-speed steel after heat treatment, Cr12MoV die steel,GCr15 ball bearing steel,9SiCr tool steel,20Cr,15CrMo,65Mn alloy steel material. It also can rough the casting wear-resistance alloy ZGMn13,can repair high hardness alloy steel with large allowance roughing, can stand with the strong interrupted turning. It is one of most popular superhard insert.

BN-H20 CBN insert: suit for finish turning high hardness alloy steel with HRC45~HRC68 hardness with high speed, such as: hard turning the 40CrMo,20CrMnTi gear after heat treatment;BN-H20 use the Ceramic bond, has a higher thermal conductivity. suit for high hardness alloy steel workpiece after heat treatment, such as: high-speed finishing hardened steel, nitriding steel, carburizing steel ,etc. case as following:

Cutting parameter of Halnn superhard CBN insert machine high hardness alloy steel

Processing material	Cutting parameter and CBN insert grade
	Cutting linear speed Vc(m/min)	Cut depth ap(mm)	Feed rate(mm/r)	CBN insert grade
High hardness steels(hardness≥HRC45)	35-90(rough)	1-10	0.15-0.7	BN-S20
	60-120(finish)	≤1	0.05-0.35	BN-S20 or BN-H20
Super alloy (hardness≥HRC35)	200-500(rough)	1-10	0.2-1	BN-S20
	500-1500(finish)	≤1	0.05-0.3	BN-S20 or BN-H20

High hardness alloy steel include the hardened steel, heat-resistant alloy, such as: alloy steel 3Cr2Mo,4Cr5mOv1Si which widely used for mould material, the hardness was usually was between HRC45 to HRC68,some Nitride steel was above HRC65.

When machining this high hardness alloy steel, we usually use BN-H20 grade insert

when the machine work piece which allowance is more than 0.5mm, BN-S20 CBN insert will be better.

More information ,please check http://www.halnntools.com/news/know/150.html, Or contact with us halnntools@gmail.com ,skype:cbn_inserts_angels