The hardness of PCBN Insert is only second to Diamond Tools, But compared with diamond tools, the Affinity between PCBN Insert and Ferrous metal is so small. When machining ferrous metal, we will choose PCBN Inserts. Compared with ceramic cutters and carbide insert, pcbn inserts will have higher hardness, wear resistance and excellent thermal stability conduct thermal performance and lower friction. And in some condition, PCBN Inserts can realize finishing instead of grinding, which will help the products to obtain higher precision and better surface quality. So PCBN Inserts have so many advantages in the process, and help the manufacturers obtain large benefit. So in modern times, PCBN Inserts are already widely used for auto, aerospace and other energy industry.
PCBN Inserts often used for machining hardened steel, bearing steel, tool steel, ductile cast iron and other high hardness materials, and the tool wear can’t be avoid. Usually we thought the wear type has 2 types: Rake face wear and flank wear. When the wear amount reach some amount, we can’t promise the product quality, even the tool will be damage. So the tool wear and the tool life have close contact. So now we will share you the factors that affect the tools wear as follows:
The Common Wear Patterns and caused of PCBN Inserts
1.Rake face wear
The main wear pattern of PCBN Insert on the rake face is the crescent worn, and the wear begins at the beginning of the cutting. Crescent Depression is mainly caused by mechanical wear and diffusion wear. Crescent Depression wear occurs mainly on the chamfer of the PCBN Insert Rack Face. In addition to the crescent worn wear, the cutting edge crack also is the wear surface of the PCBN Insert Rack Face. The generation of the micro-cutting blade is related to the strength and toughness of the tool material. When cutting the carbide with a PCBN Insert, the microcirculation and microcracks are found on the rake face of the tool. This phenomenon is produced due to the strong compressive stress during the cutting process.
2. Flank wear
Different with the rake face, the flank face amount of the PCBN Insert is very small at the beginning of the cutting, and even begins to wear after a period of cutting. With the cutting process, the flank wear began to gradually increase, the main surface of the flank wear is the groove wear. Due to the presence of hard particles in the workpiece, the workpiece and the insert produce continuous fiction in the process and it exist large pressure between them, the cbn particle fall down then become the groove wear.
3.Tools Break
Above wear pattern belong to normal wear in the process. But if the working condition is not suitable, or choosing the wrong cutting tools materials, the tools can’t obey the pressure. The cutting tools will probably break. So we need to make sure the working condition is suitable for the tools.
The factors that affect PCBN Insert wear and the tool life
(1) The content of CBN
(2) The Binder
(3) The shape of the insert
(4) The Cutting Parameter(Cutting Speed, Feed Rate and Cutting Depth)
(5) Cutting Condition(Dry or Wet)
(6) The materials of the workpiece
So the methods of improving the tool life of the insert will have the following tips:
1. Improve the cutting data
2. Change the insert chamfer
3. Make Coating on the insert.
Anyway, when you would like to improve the processing efficiency, you’d better to ask the professional engineer, they will help you make the whole solutions. Or you can tell me your problems through email info@halnntools.com, Or leave message for me Whatsapp:+8615617635382