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PCBN Inserts for Brake Disc/Drum

 1. Halnn CBN Materials for machining Gray Cast Iron

Insert Grade

Suited Materials

Machining Type

Typical Application

BN-S300

Gray Cast Iron

Roughing, Finishing

Brake Disc, Cast Iron Engine,Gearbox, Cylinder Liner

BN-S30

Gray Cast Iron

Roughing

Brake Disc, Cast Iron Engine,Gearbox, Cylinder Liner

BN-K20

Gray Cast Iron

Semi-Finishing, Finishing

Brake Disc, Cast Iron Engine,Gearbox

BNK30

Gray cast iron, Iron based alloy

Semi-Finishing,Finishing

Brake Disc, Brake Drum, Cast Iron Engine, Gearbox


2. The cutting condition of Halnn CBN Insert

CBN Content

Characteristics

Halnn CBN

Cutting Depth

Condition

High Content

Toughnes(Roughing)

Hardness (Finishing)

BN-S30

1-10mm

Semi-Interrupt

BN-S300

≤2mm

Continuous

BNK30

≤1.5mm

Continuous

BN-K20

≤0.5mm

Continuous


3. The advantages of Halnn CBN Inserts machining gray cast iron part
(1) Improve Efficiency: Compared with coating carbide insert, it can realize high speed machining,and the suitable linear speed will be: 250~450m/min for roughing process, 450~800m/min for finishing process. And it also be suitable for the high speed milling with 1500m/min or above. The efficiency will be about 2 times more than cabide insert.
(2) Improve Tools Durability: The tool life of Halnn CBN Insert is about 15 times of carbide insert.
(3) Improve Roughness: Halnn BN-K20 and BN-S30 can receive the roughness within Ra1.6, is much better than carbide insert.
(4) Characteristics of Halnn CBN inserts: BN-S30 and BN-S300 adopt non-metal adhesive, improved the thermal conductivity and the strength, not only extand the insert lifetime, but also improve the impact resistance. And BN-S30 can be used for roughing process, BN-S300 can be used for finishing process. BN-K20 and BNK30 belong to brazed pcbn insert, both of them can be used for finishing process.

 cbn inserts for machining gray cast iron

Application Case 1

Item Brake Disc Manufacturer Advantages compraison

Component Materials

GG25(HT250)

With BN-S300 Solid cbn insert, The tool life improved 45%

Machining Condition

Roughing,dry cutting

Selected Insert

BN-S300 CNGN120716

Cutting Parameters Vc=950m/min,Fr=0.7mm/r,ap=2mm


Application Case 2

Item Brake Disc Manufacturer Image
Component Materials GC250 (HT250)
Machining Process Finishing, Dry Cutting
Hardness HB180~HB220
Selected insert CNGN120412
Testing Performance Comparison

Insert Materials

Cutting Parameters Machining Qty

Halnn BNK30

Vc=1150,Fr=0.2,ap=0.25 640

Other PCBN

Vc=880,Fr=0.2,ap=0.25 475

The tool life improved 35%, and the efficiency improved about 30% !

Application Case 3

Item Brake Disc Manufacturer Image
Component Materials GC250 (HT250)
Machining Process Finishing, Dry Cutting
Hardness HB210
Selected insert BN-S300 C06 SCGN090412
Testing Performance Comparison

Insert Materials

Cutting Parameters Product Image

Halnn BN-S300 C06

Vc=900,Fr=0.25,ap=0.3

The Tool Life of Coating CBN Inserts improved about 30%, And the roughness Keeped Ra1.6

Application Case 4

Item Brake Disc Manufacturer Image
Component Materials FC250 (HT250)
Machining Process Finishing, Dry Cutting
Hardness HB170~HB210
Selected insert BNK30 TNGA160408-6S
Testing Performance Comparison

Insert Materials

Cutting Parameters Machining Qty

Halnn BNK30

Vc=1000,Fr=0.2,ap=0.3 160

Other PCBN

Vc=800,Fr=0.2,ap=0.3 100

The tool life improved 60% !

Application Case 5

Item Brake Drum Manufacturer Image
Component Materials FC250 (HT250)
Machining Process Finishing, Dry Cutting
Hardness HB170~HB210
Selected insert WNGA080408-6S
Testing Performance Comparison

Insert Materials

Cutting Parameters Machining Qty

Halnn BNK30

Vc=650,Fr=0.2,ap=0.5 120

Other PCBN

Vc=650,Fr=0.2,ap=0.5 70

The tool life improved 40% !

 Application Case 6

Item Brake Drum Manufacturer Image
Component Materials FC250 (HT250)
Machining Process Roughing, Dry Cutting
Hardness HB170~HB210
Selected insert BN-S300 CNMN120712
Testing Performance Comparison

Insert Materials

Cutting Parameters Machining Qty

Halnn BN-S300

Vc=500,Fr=0.55,ap=2 200

Other PCBN

Vc=180,Fr=0.2,ap=2 30

The tool life improved 1.8 Times!

Application Case 7

Item Brake Drum Manufacturer Image
Component Materials GC250 (HT250)
Machining Process Finishing, Dry Cutting
Hardness HB170~HB210
Selected insert CNGN120412
Testing Performance Comparison

Insert Materials

Cutting Parameters Machining Qty

Halnn BN-S300

Vc=1150,Fr=0.2,ap=0.25 640

Other PCBN

Vc=880,Fr=0.2,ap=0.25 471=5

The tool life improved 35%, and the Efficiency improved about 30%!


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