Halnn—A Complete Solution for Gear Machining After Heat Tre

1. Continuous Cutting:The inner bore and gear shaft are machined by turning instead of grinding.
Cutting State:Continuous Cutting,Dry Cutting.
The processing case is shown in the figure below.

Machining Part	Gear Wheel
Machining Materials	Hardened Steel
Workpiece Hardness	HRC58-63
Machining Type	Continuous Turning
Insert Model	BN-H10 CNGA120408S01020
Cutting Parameters	Vc=180m/min,Fr=0.1mm/r,ap=0.2mm
Machining Effect
Insert Materials	Cutting Speed	Tool Life/Edge	Efficiency
Halnn BN-H10	180m/min	800 pcs	6 s / pcs
Ceramic Insert	130m/min	150 pcs	8.5 s / psc

PCBN tool brand BN-H10 is recommended for continuous cutting:
The wear resistance and collapse resistance of BN-H10 are balanced.Roughness within Ra0.4 can be obtained by machining with it.BN-H10 is a edge-welded CBN cutter. The cutter drawing is as follows:

The cutting tool BN-H11 can also be used for continuous cutting：
Specialty:More CBN cutting edge makes the processing cost lower.The tool structure of BN-H11 is shown in the figure below.


Cutting parameters that are frequently used for continuous cutting
Linear velocity：Vc=120-230m/min；fn=0.06-0.25mm/r
Back cutting depth：ap=0.15mm；Dry Cutting.
Discontinuous gear cutting cases and the brand description of the Cutting Tools for Finishing：Gear needs to be machined after quenching its end face.However, when there are bolt holes on the end face of the gear or oil holes in the inner hole of the gear, there will be a process of "intermittent processing" in hot finishing.This process requires excellent fracture toughness and collapse resistance of the tool. In this case, brands BN-H20 and BN-H21 are generally selected.

Machining Part	Gear Wheel
Machining Materials	Gear Steel
manufacturing procedure	HRC58-63
Machining Type	Medium Intermittent Cutting
Insert Model	BN-H20 WNGA080408S01020
Cutting Parameters	Vc=120m/min,Fr=0.1mm/r,ap=0.25mm
Machining Effect
Insert Materials	Cutting Speed	Tool Life/Edge	Single Tool Fee
Halnn BN-H20	120m/min	700 pcs	0.1$
Other PCBN Insert	120m/min	650 pcs	0.1$

BN-H20 brand tools for intermittent cutting：
Medium intermittent cutting with PCBN inserts are more economical.
Cutting line speed:Vc=100-180m/min,fn=0.07-0.15mm/r
Intermittent Cutting with New product BN-H21 tools.BN-H21 is a strong intermittent cutting tool which is welding insert composite structure.
2. High Allowance Cutting or Rough Machining Tool Machining Cases After Heating
The BN-S20 brand integral PCBN tool can be used for rough machining and discontinuous machining of hardened steel with large allowance.Its single side back feed ap up to 7.5mm.BN-S20 can be used for machining hardened gear rings, repairing molds, and rough turning other hardened steel (hardness HRC45-HRC68) parts instead of grinding.

The case is shown in the diagram below
BN-S20 cutting tools can be used for carburized steel in strong intermittent cutting.The deformation of large gear (gear ring) after carburizing and quenching is serious.The outer ring deformation of gear ring is up to 2mm.The hardness of gear after quenching is HRC60-HRC65.
Cutting Line Speed:50--70m/min
The Depth of The Turning:1.5--2mm 
 Feed Per Revolution:0.12-0.2mm

Machining Part	Gear Wheel
Machining Materials	Hardened Steel
manufacturing procedure	HRC60
Machining Type	Finish Turning
Insert Model	BN-S20
Cutting Parameters	Vc=90m/min,Fr=0.12mm/r,ap=2.5mm
Machining Effect
Insert Materials	Cutting Speed	Tool Life/Edge	Final Failure Mode
Halnn BN-S20	90m/min	5 pcs	Normal Wear and Tear
Other PCBN Insert	45m/min	0.3 pcs	Destroied

BN-S20 CBN tools have better impact resistance than the original imported cutting tools.Its life is 6 times that of the original cutting tool when the cutting depth is increased by 3 times and cutting efficiency increased by 6 times.

Or feel free to contact with us info@halnntools.com, Whatsapp:+8615617635382.