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PCD/PCBN Tools for Rollers

Mill Rolls are Important Tools and Key Components for Rolling Ferrous Metal Materials. the Cost of Mill Rolls is about 5%~15% of the Rolling Steel Production, Which is Directly Related to the Production Efficiency, Product Quality and Production Cost of the Steel Enterprises.  Mill Rolls Can be divided into Casting Rolls, Forging Rolls, Tungsten Carbide Rolls. All of them have High Hardness and Large Allowance, and are difficult To Process. Especially for the Large Casting Rolls with the Casting Defects such As Sand, Stomata and Hard Spot , It will required the high hardness of Cutting Tools.

Specific for the High Hardness Rolls, Halnn Tools Recommend the Solid CBN Inserts Which can be used for Large Margin Cutting. Compared with the Traditional Cutting Tools, the Solid CBN Insert’s Performance is more Stable, and the Production Efficiency Will be Improved, and the ary cutting applications significantly reduced the Production Costs. Tungsten Carbide Ring is also called Tungsten Carbide Alloy Roll Ring ( WC Rolls or TC Rolls), We Process them with CBN and PCD Tools . Normally, CBN Inserts are Generally used for Rough Turning Tungsten Carbide Rolls Which Hardness ≤ HRA88. PCD Tools are mostly used for Finish Turning Cylinder, Chamfering and Engraving.

RNMN Solid CBN Inserts

RCMX-V Solid CBN Inserts

RCMX-Y Solid CBN  Inserts               

  PCD Notching Tool

PCD Engraving Tool

    

   

  

      

      


With more than 15 years experience, Halnn have researched one by one new materials Grade, New Technology and become the most Famous Cutting Tools Brand in Superhard Cutting Tools Industry. Specific above Casting defects and other problems, Halnn reserached some CBN Inserts and PCD Tools for Machining these High Hardness Rolls.

Halnn Grade

Type of Inserts

Machining Materials

BN-K1

Solid CBN Inserts

High Hardness Cast Iron

BN-S20

Solid CBN Inserts

High Hardness Steel/ forging Steel

BN-S300 / BN-S200

Solid CBN Inserts

Tungsten Carbide ( ≤ HRC88 Hardness)

CDW010

PCD Tools

Tungsten Carbide Ring


Recommend Cutting Parameters for Machining Different Materials Mill Rolls

No.

Rolls Materials

Wokring Layer Hardness

Recommend Cutting Parameters

1

High Chrome Nickel Cast Iron

HSD72-82

Roughing

Vc=15-30m/Min,Ap=3-7mm,f=1-2.5mm/r

Semi-Finishing

  Vc=20-40m/Min,Ap=4mm,f=1.5-2.5mm/r

2

High Chrome Cast Iron

HSD72-78

Roughing

   Vc=10-20m/Min,Ap=3-7mm,f=0.50-1.2mm/r

Semi-Finishing

  Vc=15-30m/Min  Ap=4mm   f=1.5-2.5mm/r

3

Casting High speed steel

HSD82-90

Vc=5-15m/Min   Ap=3-8mm f=1-2.5mm/r

4

Casting Semi-Steel

HSD55-65

Vc=30-60m/Min  Ap=4mm   f=1.5-2.5mm/r

5

High Carton Semi-Steel

HSD65-72

Vc=25-50m/Min  Ap=4mm   f=1.5-2.5mm/r

6

Chilled Cast Iron

HSD50-70

Vc=25-50m/Min  Ap=4mm   f=1.5-2.5mm/r

7

High Chrome Cast Steel

HSD68-75

Vc=20-45m/Min  Ap=4mm   f=1.5-2.5mm/r

8

Tungsten Carbide Rings

HRA88

Vc=15-60m/Min  Ap=0.2-0.5mm   f=0.1-1 Mm/r

9

forging 9Cr2Mo

HSD92-105

     Vc=10-25m/Min  Ap=1mm   f=0.5-1.2 Mm/r


Aplication Case

(1). BN-K1 Solid CBN Inserts Rough Machining High Ni-Cr Alloy Cast Iron Rolls 

Rough Machining High Ni-Cr Alloy Cast Iron Rolls

Machining Material

Hardness of Workpiece

Selected Halnn Insert

Cutting Condition

High Ni-Cr Iron

HSD80

BN-K1 RNMN120400 and SNMN120712

Ap=9mm,Fr=0.5mm/r, Vc=25m/min

Selected Insert

Efficiency

Workpiece

Halnn BN-K1

Improved 3 Times

 

Carbide Insert

 

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(2)BN-K1 Solid CBN Inserts Machining Semi-Finishing Chilled Cast Iron Rolls  

Semi-finishing Chilled Cast Iron Rolls

Machining Material

Hardness

Selected Insert

Cutting Condition

Chilled Cast Iron Rolls

HSD67

BN-K1 SNMN

Ap=2mm,Fr=0.5mm/r, Vc=66m/min

Selected Insert

Efficiency

Lifetime

Workpiece

Halnn BN-K1

Improved 3 times

3 times

 
Carbide Insert


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(3)BN-S20 Solid CBN Inserts Turning High Speed Steel Roll     

Turning the Repairing Threaded Steel Roll

Machining Material

Hardness

Selected Insert

Cutting Condition

High speed steel Rolls

HRC60

BN-S20

Ap=0.5mm,Fr=0.5mm/r,Vc=25m/min

Selected Insert

Efficiency

Workpiece

Halnn BN-S20

5 times

                                       

 

Carbide Insert

 

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(4)BN-S20 Solid CBN Inserts Finish Turning forged Steel Cold Rolls    

Finish Turning Forged Steel Cold Rolls

Machining Material

Hardness

Selected Insert

High speed steel Rolls

HRC60

BN-S20

Selected Insert

Efficiency

Halnn BN-S20

5 times

 

Carbide Insert

 

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(5)Halnn Tools BN-S300 CBN Turning Tungsten Carbide Rings    
CBN Turning Tungsten Carbide Rings

Machining Material

Hardness

Selected Insert

Cutting Parameters

Tungsten Carbide Rings

HRA88

BN-S300

Vc=15m/min,ap=1mm,fr=0.3mm/r

  


Workpiece


(6)Halnn PCD Tools machining Tungsten Carbide Rolls  

         PCD Inserts Turning Tungsten Carbide Rolls

PCD Turning Tungsten Carbide Rings

Machining Material

Hardness

Selected Insert

Cutting Parameters

Tungsten Carbide Rings

HRA88

CDW010

Vc=15m/min,ap=1mm,fr=0.3mm/r

 

                   
                      Workpiece

     




PCD Notching Tools

PCD Notching Tools

CVD Engraving Tools

RCMX PCDTools

  

   

           



 

 

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