Roughing the Pump casing with BN-S20 solid CBN insert

Roughing the Pump body with BN-S20 solid CBN insert

Roughing the surface roller with BN-S20 solid CBN insert

The structure and processing characteristics of the CBN inserts

With the rapid development of machinery manufacturing industry, more and more materials and Superhard materials which difficult to machine were widely used, machining tool is also a severe test, development of various good wear resistance, thermal stability, impact excellent Superhard cutting tool is an inevitable trend. Efficient processing, hard machining, dry machining, ultra-precision machining difficult materials and new machining direction of the tool is the development of the industry, CBN is the most advantageous tool material for machining high hardness as the current difficult to machine ferrous materials , is the future for precision and ultra-precision machining of the necessary tools.

Currently, CBN insert has a strong competitiveness in many machining of automotive, aerospace and medical equipment and other industrial fields .Mounting the CBN insert in the machine tool which has a good steel can take advantage of the CBN tools performance , CBN inserts also save the manufacturer costs , when you have a more favorable opportunity to improve productivity.

Part 1 Formal structures Category of the CBN inserts

1.Solid CBN inserts
Solid CBN blade has good wear resistance and impact resistance, especially when processing the cast iron material which ferrite-containing less than 10%.Large margin roughing and finishing are both OK, it greatly improved processing efficiency and reduce processing costs, as more and more high hardness castings produced by the more customers, the future market share there will be a big surge.

 2, composite CBN inserts
Composite CBN insert choose a better carbide substrate, the edge portion of the insert welded the CBN material, it has good wear resistance, mainly used in finishing material which hardness was more than HRC45 and a small margin, can get a well finish and dimensional accuracy.

 3. Mosaic CBN inserts
The so-called mosaic CBN inserts is a complete top surface sintered on a cemented carbide substrate, providing multiple cutting edge on just one side of of the tool, this tool is cheaper than the composite tool and can be made more cutting edge, largely reducing the processing costs, but mainly for the finishing process, control unilateral knife to eat in less than 0.3mm depth is well, enabling high-speed turning, finish up Ra0.8-0.4.

Part 2 The processing characteristics of CBN insert :

1.Suitable for processing materials with high hardness
 As CBN tools hardness rank only second to diamond, CBN and diamond tools are both name super-hard tools, the CBN tools mainly for machining ferrous materials with high hardness, the hardness of work piece control in general HRC45 or more, the processing effect is not ideal if the hardness less than HRC45.

Halnn superhard, the leader specializing in hard materials processing tools, mainly for research and development of the tools for high hardness and difficult machined material, such as Halnn developed a superhard BN-K1 grades CBN inserts, can machine the workpiece which has a high hardness HRC79, which is unimaginable before, but with the constant study and practice tool industry from Halnn Superhard tools company, ultimately be achieved.
 2. Roughing with large margin 
Integral CBN insert can achieve a large margin roughing, such as Halnn superhard company developed Integral CBN BN-S20 grade insert, depth of cut can up to 8mm, can eat over the entire insert, production efficiency was increased exponentially.
 3. High-speed cutting
Due to CBN tools good performance, can be fully realized high-speed cutting, and can be the perfect combination of CNC machine tools, efficient cutting of the workpiece greatly improved production efficiency.
Such as Halnn superhard companys CBN tools speed can reach 1500m / min when finishing without considering the lathes rigidity and clamping manner . Gray iron can be achieved high-speed cutting, and get a good finish and dimensional accuracy.
 4 Dry cutting

CBN tools have a high hot red hardness, if add coolant, its blade easily happen to crack when temperature plunged, so CBN inserts general machine the workpiece use dry machine , especially in the case of intermittent cutting, dry machine was not only environmentally friendly but also save some costs.
Part 3 Summary
CBN inserts is the best tool machining ferrous metal materials currently, with the application of high hardness and difficult materials increasingly widespread in the future, CBN blade market share will gradually increase, CBN insert will become the mainstay of hard materials processing industry in the future.

Halnn Superhard tools has the technology to process the slurry pump and its parts

With the highspeed development of Chinese economy. A variety of light and heavy industry rose and developed quickly,slurry pump demand is also increasing,how to manufacture and process an excellent performance in all aspects of slurry pump became the goal of continuing to explore contemporary academia.This article describes the usage and material, and the tools which suit for processing the of  slurry pump parts.

Part 1 The usage and the material of the slurry pump

Slurry pump can also be called centrifugal pump, it is a equipment which use the rolling power of the centrifugal pumps impeller with the help of the is the role of the rotating pump impeller to increase the energy with mixing solid and liquid media,and convert electrical energy into kinetic and potential energy of the medium.

As slurry pump works in poor conditions,commonly working in strong acid,alkali or other corrosive substances environment,leading to short life,for obtaining a longer life of slurry pump,we used in high strength and hardness,corrosionresistance and and strong highchromium alloy cast iron as the main material of the slurry pump,such as Cr15Mo3,Cr15Mo2Cu,KmTBCr12, Cr20, Cr26,etc.

The hardness of the High-chromium alloy can reach about HRC60, it is one of the best current performance wear-resistant materials,mainly widely used in mining,electricity, metallurgy,coal,transport and environmental protection industrieswhich abrasive slurry containing solid particles. Slurry pump named differently with its different environment it works, as in the coal washing indu-stry, sea and sand dredging election and other fields, also known as mud pumps, mud pumps, etc.

Part 2 Technology to process the slurry pump parts

There are many Slurry pump parts, the main components includes impeller, shaft, jacket, front fender, rear fender, pump casing and shaft seal devices. the role of the impeller is transmitting the original motivation of the mechanical energy to the liquid directly, for increasing the static pressure energy and kinetic energy(mainly increase static pressure)of the liquid.The shaft sealing device is used for preventing the liquid in pump housing leak along the axis or ambient air leaking into the pump housing. 

The technological process of the Impeller: Rough turn import port ring and front panel----Pure front mouth ring and inner hole(Ensure the concentricity requirement)----Insert keyway (guarantee the keyway symmetry degree)----Drill Impeller balance holes(uniform size distribution)---Test (balance test)--- Checkout. 

The technological process of the pump shaft: Rough turn----heat treatment (quenching)---- Half finished turning---- finish machining---keyseat---- external grinding---checkout.

Slurry pump impeller is the only working part, it is often made of Cr26 as the main material. impeller has 5~12 blades,it is difficult to process when using the lathe. One of the seasons is Cr26(high chrome cast iron) has a high hardness after casting, and some large castings casting defects usually happened, such as white, hard particles, etc. the second season is the impeller need to intermittent cutting wheel, which adds to the difficulty of processing.

Part 3 How to choose the cutting tools for processing slurry pump

There are three types of tools to processed slurry pump parts on the market today: carbide-tipped tool,ceramic cutting tools and cubic boron nitride cutting tools. Personally CBN tool is the most suitable for processing slurry pump components.

Since the slurry pump parts has a high hardness after manufacturing or heat treatment, so it is difficult to process. Machinery Manufacturers earliest used the carbide cutting tools for machining slurry parts, but due to the carbide cutting tool is not hardness enough, uneven surface will be happened when processing the slurry pump parts especially the large-scale processing of casting, being casting defects. carbide Tool wear out fast when processing, is necessary to change a new still not finish one part, impacting the processing efficiency and cutting tool costs high.

So as the ceramic cutting tools,it is unnecessary to explain it again. You can choose ceramic cutting tools if you precision process the small feed part and ignore the whole benefit of your company.

These two tools are not a good solution to the problem which difficult to process slurry pump, then we developed a cubic boron nitride cutting tools(CBN). Halnn company developed non-metallic adhesive superhard cubic boron nitride cutting tools BN-K1 grade,so process the rough slurry pump parts came into reality. In terms of the hardness:Halnn superhard BN-K1 grade=conventional CBN tools> Ceramic knives> Carbide Tool; for the toughness: Halnn super-hard BN-K1 grades>Traditional cubic boron nitride cutting tools> carbide Tool>Ceramic tool;

Halnn super hard tools, the pioneer in superhard tools, the leader of professional hard materials processing tool, the domestic first proposed roughing "CBN overall polycrystalline Blade" concept, non-metallic adhesive cubic nitride boron tool widely used in high hardness materials, high hardness workpiece after heat treatment, and other difficult to cut materials, parts and other fields, moreover it also break the monopoly of foreign materials which has high hardness processing difficultly, enjoyed a high reputation superhard cutting tool in academia .

The advantages of Halnn non-metallic binder CBN super-hard tools BN-K1 grades: compared with carbide tools, it has a high hardness, good wear resistance; compared with ceramic cutting tools and conventional cubic boron nitride cutting tools,it   has Anti Shocking, can be intermittent cutting impeller slurry pump parts.

Here's a brief of Halnn super hard tool process slurry pump parts(impeller) case.

Part 4The slurry pump impeller’s machining case from Halnn super-hard non-metallic binder CBN tools BN-K1 grades   

Materials: high-chrome cast iron Cr26;

Manufacturing process: Turning cylindrical, face;

Tool grades: BN-K1 grades;

Cutting data: Vc= 75m min, ap=2.5~5mm,Fr=0.1mm/r;

Processing methods: intermittent cutting; dry cutting.

Processing effect: When turning the impeller,as there are 5-12 blades on impeller,the cutting Tool will bear 5~12 times impacting when the impeller rolls per round. BN-K1 grades CBN tool cutting process intermittently does not produce fractured, and the BN-K1 grades cutting speed of Halnn super-hard non-metallic binder cubic boron nitride(CBN) tool speed is higher than the ceramic tools, at same time the life of the single Blade is seven times than ceramic tools, showing the impact resistance of non-metallic binder cubic boron nitride(CBN) cutting tools well, not only reduces the cost of the tool, turning efficiency is also improved.

Material of the cutting tools	Cutting Speed	Life of single blade	Wear degree
Halnn BN-K1	75m/min	7 pieces	Normal wear
Other brand ceramic cutting tools	35m/min	1 piece	Crash damage fracture

Part 5 Conclusion

With the continuous development of modern technology, machinery manufacturers are trying to make a better working life of the workpiece,just like slurry pump industry are also using more corrosion resistant high chrome cast iron as the main material, this is a challenge to the cutting tool field, in the face of the case, there is no way except developing high-quality high performance and efficiency tool material, so that we can follow the development of the times

Wear-resistant materials and Machinery manufacturing related to cutting tools industry

With the continuous development of modern technology, more and more machinery manufacturing have high demands for product quality and usage life. Improve the products quality and usage life become a reality, because the development of machinery manufacturing industry has made an outstanding contribution for the world.

Wear-resistant material is a kind new materials with special electrical, magnetic, optical, acoustic, thermal, power, chemical and biological function. It is an important base material of information technology, biotechnology, energy technology etc high-tech field and national defense construction

Currently, the classification of wear-resistant materials can be divided into: wear-resistant ball, wear-resistant steel plate, wear-resistant welding rod, wear-resistant ceramic, wear-resisting flooring, wear-resistant rubber, wear-resistant pipes, wear-resistant bearings, wear-resistant welding consumables, wear-resistant castings, cast stone, polymer other resistant materials.

Following will share above classification:

1. Wear-resistant ball: Wear-resistant ball is a kind of ball mill grinding media. Chrome as for the main element, called chrome alloy cast iron grinding ball; Another material is ductile iron casting grinding ball, called ductile iron grinding ball, which in turn contains bainite ductile iron grinding ball and martensite iron ductile iron grinding ball.

Widely used in metallurgy mining, cement building materials, thermal power, magnetic materials, chemicals, coal slurry, pellets, slag, fly ash, quartz sand ball mill industries.

2. Wear-resistant steel plate: At present, Common used wear-resistant steel plate are obtained wear-resistant steel plate through some processes, widely used in metallurgy, coal, cement, electricity, glass, mining, building materials, bricks and other industries.

3. Wear-resistant welding rod: Wear-resistant welding rod of different materials are used for different workpiece. Widely used in metallurgical machinery, mining machinery, jaw plate, bucket, shovel teeth, spiral, mixer blades, fan blades, mineral processing machinery, engineering machinery, building materials machinery and other fields.

4. Wear-resistant ceramic:Al2O3 as the main raw material, rare metal oxide as for solvent, through the 1700℃ high temperature roasting special corundum ceramics, and then separately with special rubber and high strength organic/inorganic binder combination to form products. With high hardness, high wear resistance, light weight, strong adhesion, good heat resistance and other advantages. Widely used in the steel industry, cement industry, the port industry, metallurgy industry, chemical industry, Coal industry, mining and other industries.

But in use process must be a full analysis and research aiming at ceramics usage work conditions, including the following factors can affect the performance of wear-resistant ceramic:

① Usage temperature range and variation;

② Corrosive media;

③ The stress situation;

④ Hard particle collision angle of incidence;

⑤ Particle Erosion strength;

5.Wear-resisting flooring: Metallic wear-resistant floor, non-metallic wear-resistant flooring and alloy aggregate. Anti-stress, strong wear resistance, and can not afford to dust, enhanced ground anti-oil, anti-infiltration and easy to clean.

6. Wear-resistant pipes: Also known as wear-resistant pipes, wear-resistant pipe materials, main including abrasion resistant straight pipe, elbows and other structural parts. It is a transportation pipeline of pneumatic, pumping slurry etc. corrosion resistant materials. Widely used in electric power, metallurgy, coal, petroleum, chemicals, building materials, machinery and other industries.

7.Wear-resistant welding consumables: Wear-resistant welding rod, welding wire can be called wear-resistant welding consumables, it got good wear resistance by build-up welding, spray welding and other processes, resulting in longer life. Widely used in metallurgical machinery, mining machinery, jaw plate, bucket, shovel teeth, spiral, mixer blades, fan blades, mineral processing machinery, engineering machinery, building materials machinery and other fields.

8.Wear-resistant castings: Containing wear-resistant cast iron parts and wear-resistant cast steel parts. Add some wear-resistant materials or elements, such as chromium, nickel and other alloying elements during casting, get a higher wear resistance. Collectively known as wear-resistant castings.

If you would like to machining these wear resistant materials ,you need to choose the suitable cutting tools ,cbn will be the best choice for you. Halnn Superhard is a professional cbn insert brand in China .More information on cbn cutting tools ,you can check http://www.halnntools.com/pro/ ,Or send me email halnntools@gmail.com

Halnn Superhard CBN cutting tools processing auto cast iron parts solutions

Auto parts are made from gray cast iron with a variety of shapes, the choice of cutting tools to be considered the tool and the work piece gap, must not have any interference.

Halnn Superhard provide professional and efficient cbn cutting tool according to process various structural automotive cast iron parts. Select different cutting tools model number according to different parts, not only increase productivity, but also reduce processing costs.

1.Auto parts brake disc processing

① Roughing: Select Halnn superhard developed non-metallic adhesive CBN insert BN-S30 grades, is also suitable for the finishing procedure, when roughing brakes disk, often using rhombus inserts and square inserts. High processing efficiency, and can well controll precision demand. such as CNMN120416, CNMN120718; SNGN120412; SCGN0904 brakes are usually used to roughing brakes disc inserts model number.

Halnn Superhard non-metallic binder CBN inserts BN-S30 grades features:

1).High hardness, good wear resistance;

2).Non-metallic (ceramic) as a binder, a strong impact toughness;

3).Good stability and good reliability;

4).It can meet all kinds of machine tools cutting processing;

5).High-speed cutting efficiency high;

6).Dry Cutting reduce environmental pollution;

②Fine finishing: Halnn Superhard cubic boron nitride inserts BN-K20 grades belong welded CBN inserts, only suitable for a small margin for fine finishing procedure. Inserts have many models, such as the triangle, rhombus, etc., VNGA120408; WNGA080408; TNGA160408. Fine finishing cutting speed can reach up to 1500m / min. The cutting tool can withstand high-speed cutting in the case of machine tool rigidity enough. Processing efficiency is 20 times of coated carbide inserts.

2. Auto parts engine block processing

Automobile parts engine cylinder mainly adopts milling processing, Halnn superhard latest launched overall cubic boron nitride inserts BN-S300 grades, can high efficiently milling engine block. Such cutting tools are more resistant, higher processing precision, overall rigidity and stability is very good, especially suitable for the milling engine cylinder surface.

Halnn superhard CBN inserts BN-S300 grades fine milling engine block cutting parameters: ap = 0.3mm,Fz=0.12mm / r, line speed n=2800,Vc=1700m/min. Compared to imports PCBN inserts, 3670mm/min feed rate, Halnn superhard BN-S300 grades cubic boron nitride cutting tool life is higher than imports PCBN cutting tools, and cutting tool costs is less than imported PCBN inserts.

3. Auto parts belt pulley processing

Auto Parts belt pulley finishing cutting tool selection BN-K20 grades. BN-K20 grades cutting tools are mainly used for gray cast iron fine finishing procedure. In addition to the processing belt pulleys, Halnn superhard BN-K20 grades cubic boron nitride inserts can also be processed clutch pressure plate, flywheel, axles axle housing and other gray cast iron materials.

Cutting parameters: ap=0.3mm, Fr=0.25mm/r, Vc=550-700m / min. Compared to coated carbide cutting tools: not only ensures a good belt pulley roughness and cutting tool life is 5.5-6 times of coated carbide cutting tool.