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PCBN Tools for Hard Turning

1. Halnn CBN Materials for Hard Turning

CBN Grade

Blinder

CBN Content

Granularity (μm)

Hardness

BN-S20

TIN

76

4~6

2900-3100

BN-S200

TIN

60

2~4

2800-3000

BN-H11

TIN

70

2~4

2800-3000

BN-H20

TIC

80

2~4

3100-3300

BN-H05

TIN

45

≤1

2700-2800

BN-H10

TIN

50

≤1

2700-2800

BN-H21

AL,TINC

60

1~2

2600-2800

BN-H05 C25

TIN

45

≤1

2700-2800

BN-H10 C25

TIN

50

≤1

2700-2800

BN-H21 C25

AL,TINC

60

1~2

2600-2800


CBNContent

Characteristics

Insert Grade

Depth of Cut (mm)

Recommend Cutting condition

Suited Materials

Typical Application

Low Content CBN

Toughnes (Roughing)

Hardness (Finishing)

BN-S20

1-10mm

Interrupt-Continuous

Hardened Steel, Heat and abrasive resistant steel, High manganese steel

HSS Rolls, Ball Screw, Wind Power Bearings

BN-H20

≤1mm

Semi-Interrupt

Hardened steel, other materials of difficult to machine

Hardened Steel Gears, Mold,ect

BN-S200

≤1mm

Continuous

Hardened Steel, Superalloy

Wind Power Bearings

BN-H11

≤1mm

Continuous

Hardened Steel

Bearings, Gears, Gear Shaft, Hardened Mold

Hardness

Toughness

BN-H05

≤0.2mm

Continuous

Hardened Steel

Gears,Gear Shaft, Bearings

BN-H10

≤0.5mm

Continuous-Semi-interrupt

Hardened Steel, high strength cast iron

Bearings, Gears, Gear Shaft, High hardness component

BN-H21

≤0.5mm

Semi-interrupt—Heavy Interrupt

Hardened Steel

Bearings, Gears, Gear Shaft,Mold,ect.

Hardness

Toughness

BN-H05 C25

≤0.2mm

Continuous

Hardened Steel

Gears,Gear Shaft, Bearings

BN-H10 C25

≤0.5mm

Continuous~Semi-Interrupt

Hardened Steel, high strength cast iron

Bearings, Gears, Gear Shaft, High hardness component

BN-H21 C25

≤0.5mm

Semi-Interrupt~Heavy Interrupt

Hardened Steel

Bearings, Gears, Gear Shaft,Mold,ect.

2. Typical Application Case

BN-H10 PCBN Insert Hard turning automotive Transmission gear shaft
Component Transmission gear shaft
Materials & Hardness 20CrMo,62-65HRC
Selected Insert BN-H10 VNGA160408
Cutting Parameters Vc=132m/min,ap=0.1mm,fr=0.15mm/r
Roughness Ra1.6
Coolant Method Wet Cutting
CBN Materials Selected Insert Average tool life (pieces/tip)
Kyocera PCBN KBN25M VNGA160408 S01225 100
Halnn PCBN BN-H10 VNGA160408T01535 145
With Halnn BN-H10, tool life improved 45%!

 

BN-H05 PCBN Insert Continuous turning Gear Inner Bore

Machining Condition:

Continuous Turning

Materials & Hardness

20CrMnTi Gears,HRC58-62 

Selected Insert

BN-H05 CNGA120408  

Cutting Condition

ap=0.1mm,Fr=0.1mm/r,Vc=180m/min,Dry Cutting

Insert Materials

Roughness

Tool Life

Halnn BN-H05

≤Ra0.8

800 pieces

Other Brand PCBN

Ra1.0

550 pieces

With BN-H05 PCBN Insert, the Tool life will improve 45%!

 

BN-H10 PCBN Insert Light Interrupt turning Gear inner bore

Machining Condition

Semi-Interrupt turning inner bore

Materials

20CrMnTi Gears, HRC58~62

Selected Insert

BN-H10 CCGW09T304

Cutting Condition

ap=0.25mm,Fr=0.08mm/r,Vc=135m/min,dry cutting

Cutting Tools Materials

Cutting Speed

Tool Life

Efficiency

Halnn BN-H10

135m/min

1000 pieces

Improved 22%

Other PCBN Insert

110m/min

600 pieces

----

With BN-H10 PCBN hard turning the gears with keyway, the efficiency will improve about 22% !

 

BN-H21 PCBN Insert heavy Interrupt turning Gear EndSurface

Machining Condition

 Heavy Interrupt turning Endsurface

Materials

20CrMnTi Gears, HRC58~62

Selected Insert

BN-H21 WNGA080404

Cutting Condition

ap=0.15mm,Fr=0.1mm/r,Vc=117m/min,dry cutting

Cutting Tools Materials

Tool Life

Failure Mode

Halnn BN-H21

600 pieces

Normal Wear

Other PCBN Insert

100 pieces

Damaged

With BN-H21 PCBN Insert, the tool life improved about 5 times, it will not chip when meet heavy interrupt condition.

 

Halnn Coating PCBN Insert machining Gears
Component Materials 20CrMnTi, HRC58~62
Selected Insert BN-H05 CNGA120408
Cutting Condition Ap=0.1mm, Fr=0.1mm/r,Vc=180m/min

Insert Materials

Roughness

Tool Life (pieces/insert)

Other PCBN

Ra1.0

550

Halnn BN-H05

Ra≤0.8

800

Halnn BN-H05 C25

Ra≤0.8

1200

With Coating PCBN Bn-H05 C25, the tool life will be improved about 50% than Bn-H05 without coating.

 

BN-S20 Solid CBN Insert hard turning Ball Screw

Materials & Hardness

Rolling Screw Gcr15, HRC60-62

Selected Insert

BN-S20 CNGN120708

Cutting Parameters

ap=4.5mm,Fr=0.10mm/r,Vc=95m/min,
Dry Cutting

Insert Materials Cutting Depth Failure Mode
Halnn BN-S20 4.5mm Normal Wear
Ceramic Insert 0.5mm Damaged

BN-S20 can achieve the cutting depth 4.5mm, and also normal wear.

 

BN-H10 PCBN Insert hard turning Ball Screw Raceway

Materials & Hardness

Rolling Screw Thread Gcr15, HRC60-62

Selected Insert

BN-H10 Customized PCBN Inserts

Cutting Parameters

Fr=0.10mm/r,Vc=150m/min,
Dry Cutting

Insert Materials Roughness Failure Mode
Halnn BN-H10 ≤Ra0.8 Normal Wear
Other PCBN Inserts Ra1.2~1.6 Damaged

BN-H10 make the roughness with Ra0.8,Normal Wear

 

BN-H10 PCBN insert Hard Turning Wind Power Bearings
Materials & Hardness Wind Power Bearings 42CrMo,Hrc58~62
Selected Insert BN-H10 RNGN090300
Cutting parameters

ap=1mm(Roughing),ap=0.15mm(Finishing),Fr=0.45mm/r,

Vc=145m/min, dry cutting

Insert Materials Cutting Speed Tool Life Efficiency
Halnn BN-H10 145m/min 3pcs/blade Improve 20%
Other PCBN Inserts 120m/min 2pcs/blade Improve 20%
With BN-H10. the efficiency will improve about 20%, and the tool life improve about 50%.

 

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