The development of material of PCBN cutting tool reachs his to process medium application in milling

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Summary: Introduced type of structure of PCBN cutting tool to arrive from razor blade of type of drill rod solder the development process of integral type razor blade. Razor blade of new name SECOMAX-CBN300 uses thick grain powder (22µm) and new agglomeration technology, improved bit greatly fight concussion tenacity, the application PCBN cutting tool the turning hard data from the tradition (HRC>45) , with the car era is ground expand milling machines a domain. Raising milling to machine the fine quality of efficiency respect through machining example to mirror PCBN milling cutter. The ceaseless progress of material of cutting tool of 1 foreword cutting has very main effect in the progress that making a technology. New material brings cutting tool function raise the addition with cutting tool life, make the interchangeability that ensures according to strict dimension precision and requirement of exterior surface roughness large quantities of quantities produce a part becomes a possibility. PCBN(gets together nitrogen of brilliant cubic metre changes boron) it is the hardness in nature those who be next to diamond is mineral (microscopical hardness amounts to HV8000 ～ 9000) . To machining black metal character, the bit that PCBN material makes is hardness is highest. The hot rigid with PCBN series good bit (hear resistance amounts to 1500 ℃ of 1400 ～ ) , fight oxidisability (in 1200 ～ 1300 ℃ also do not produce chemical reaction with iron department material) and fight rupture tenacity makes its are in cutting treatment show extremely outstanding character, already applied at exceeding hard data widely at present (HRC>In the treatment of 45) . In addition, in the application that PCBN improves treatment efficiency in a lot of need very popular also. As modern manufacturing industry especially the rapid development of automobile manufacturing industry, what treatment of treatment, tall to high speed cutting, strong voice stability and the advanced cutting such as cutting doing type machine a concept to consider is ceaseless and thorough, use generally of the swift and violent development that promoted CNC processing technique and numerical control machine tool, the exceeds strong cutting tool production that can realize efficient, tall stability, macrobian life to machine and application also gain ground with each passing day. Automobile industry is many and flexible product line (FMS) offerred very good chance for the application of stuff of new name of PCBN cutting tool. According to statistic, the PCBN cutting tool of about 60% is used at automobile manufacturing industry, the PCBN cutting tool of 20% is used at heavy equipment (roller) treatment. Each grows bit of SECOMAX series PCBN specifications of razor blade of PCBN of 2 SECOMAX series sees a table 1. The content of CBN of sort of specifications razor blade that expresses razor blade of PCBN of 1 SECOMAX series (%) grain dimension (CBN150450 of whole of CBN100502TiC of whole of CBN30908Al of matrix of hard alloy of CBN20806Ti&Al of matrix of hard alloy of CBN10502TiC of type of µm) binder structure.

Whole of CBN3009022Al of matrix of 5TiN hard alloy from the watch razor blade of PCBN of company of 1 visible SECO from razor blade of type of drill rod solder (only a point) to integral type razor blade (come more 8 point) development process: CBN100 razor blade is the improvement of CBN10, it is the integral PCBN razor blade of fine grained, PCBN content is inferior (50%) , the low heat that its have conducts character to be able to make heat in metal cutting is centered in cutting area, improve the finish machining result of hard steel of temper by dipping in water greatly. The PCBN content in CBN150 is inferior also (40%) , because its structure is PCBN material solders to go up in hard alloy matrix, because this is had very outstanding fight concussion tenacity, can use at cutting state be opposite when interrupted cutting even badly quite the treatment of taller hardness workpiece. CBN300 is body of agglomeration of a kind of pure CBN, PCBN content is higher (amount to 90%) , be thick grain is used on CBN30 foundation (22µm) powder defies concussion name with what special agglomeration technology gets, have very good wearability, thermal conductivity and fight concussion tenacity, can use at interrupted cutting. With already some PCBN product photographs are compared, CBN300 is a kind of new more mature PCBN product. CBN300 razor blade can be used at pearlite ash rough machining of hard steel of the thick finish machining with cast-iron mouth, temper by dipping in water, cold hard the cast-iron treatment, treatment of manganese steel even the treatment of the material such as hard alloy. As a result of its good impact resistance, CBN300 can be used at turning treatment not only, also behave when milling workpiece at the same time outstanding, solved the difficult problem that transcends hard data to cannot cut treatment with Yu Xi, realized PCBN razor blade to use the flight of milling application from turning. CBN300 can achieve 4 times of common PCBN razor blade in the cutting tool life when milling machines casting pig; Compare with razor blade of pottery and porcelain, use CBN300 razor blade to be able to improve cutting tool life 50 times, cutting speed can amount to 2000m/min. Graph the cutting relation sketch map when 1 end mill pursues the change of force of cutting of tooth of individual milling cutter when 2 end mill pursues the compares 3 CBN300 razor blade character of hardness of material of the cutting tool below 3 different temperature in recent years, PCBN cutting tool is in pearlite grey mouth behaved uncommon character in the planar milling treatment of cast-iron engine cylinder body. Be in company of Shanghai general motors (the engine that SGM) builds is flexible on product line, apply CBN300 successfully Yu Xi to cut plane of engine cylinder body, vc is as high as milling linear velocity 1500m/min, improved the treatment efficiency of engine cylinder body greatly not only, and saved many installation cost, those who promoted engine product line is flexible degree. The metabolic rule of force of the cutting when Duan Xi pursues the cutting relation sketch map when the 1 mill that it is end. According to the derivation of Weilenmann, the computational formula of force of the cutting when Duan Xi is as follows: In the type of cutting force Fsz=bhks(1) of individual mill tooth: B -- cutting width, b=a/sink(mm) Ks -- H of unit cutting force -- cutting ply, h=Sssink(mm) ; Among them K is tool cutting edge angle, ss is feed, graph 1 in, ss ≈ Szsinf, the form of feed deflection basis that F chooses for milling of point of a knife (the cutting force of tooth of attainable individual milling cutter follows 1) the metabolic curve of F horn (if pursue,show) 2 times. The average cutting force of individual mill tooth is (in 2) type: F1 -- the feed deflection that cutting begins to be in F2 -- cutting stops the feed deflection Face=symbol>f3 of place -- the characteristic and good hot rigid of the razor blade of osculatory horn CBN300 when Duan Xi: Graph 3 it is 3 kinds of different cutting tool such as CM, TP200, CBN300 the hardness change curve that material leaves in different temperature. The graph showed a curve 3 times to show CBN300 has good hot rigid. Accordingly, compare with pottery and porcelain, hard alloy, CBN300 has admirable thermal conductivity and impact resistance. Extremely tall life and manufacturing efficiency use hard alloy razor blade and CBN300 milling vavuum pump respectively casting lid, workpiece material is HT200, thick, finish machining place sees a table with cutting parameter and cutting tool life 2. Express life of cutting tool of 3mmVf=300mm/min of ～ of Vc=150m/minap=2 of rough machining of CBN300 of razor blade of hard alloy of material of 2 cutting tool: Life of cutting tool of 3mmVf=3000m/min of 70 Vc=2000m/minap=2 ～ : Vc=180m/minap=0 of 150 finish machining.

Life of 2mmVf=500mm/min cutting tool: 100 Vc=2000m/minap=0.

Life of 2mmVf=5000mm/min cutting tool: 600 are seen by the data in the watch, no matter be rough machining or finish machining, the manufacturing efficiency that uses CBN300 is very tall: In Ap changeless circumstance falls, the tower above when Vc comparing uses hard alloy cutting tool 10 times above, vf is 10 times of hard alloy cutting tool; The cutting tool life of the CBN300 when rough machining is 1 times taller than hard alloy cutting tool, and 6 times what life of hard alloy cutting tool is when finish machining. The company of tall cutting tool of hill of mill bit body that suits to install CBN razor blade ever the first 8 blade milling cutter, make the growth of effective cutting blade of milling cutter razor blade remarkable. The milling cutter that at present hill high company develops is a lot of more phyletic, the structural design of milling cutter made sure cutting is light bit life is long at the same time. The mill bit body that suits to install CBN razor blade basically has a few kinds as follows: Bit body of mill of circular razor blade: R220.

200mm) of ～ of 70(diameter F63, the biggest rotate speed 12800 ～ 7200, tine counts 6 ～ 12, suit thick, finish machining; Bit model: RNMN090300E, bit body of mill of razor blade of form of CBN300 all directions: R220.

74(diameter 63 ～ 200mm) , tool cutting edge angle 75 degrees, comfortable at thick, finish machining; Bit model: SNEN0903ENE, CBN300. Bit body of mill of octagonal razor blade: R220.

43(diameter 63 ～ 500mm) , tool cutting edge angle 45 degrees, apply to rough machining; Bit model: OFEN070405TN - MD16, CBN300. R220 of mill bit body.

30(80 ～ 355mm) , use at finish machining; Bit model: SEEX1203AFTN - MD13, CBN300. Example of 4 milling treatment uses SNMN090312S of model of CBN300(razor blade to be used at SNMN0903ENS of model of rough machining, razor blade to be used at finish machining respectively) with hard alloy cutting tool (cylinder body of casting pig of milling of bit model SPKT1504AZN) is planar, treatment uses cutting parameter and contrast of cutting tool life to see a table 3. Express D=160mm of diameter of bit body of rough machining of CBN300 of hard alloy of material of 3 cutting tool, tine counts SPKT1504AZNAe=120mm of model of Z=20 razor blade, ap=5mm, vf=300mm/min, life of Vc=160m/min cutting tool: D=160mm of diameter of 60 bit body, tine counts SNMN090312Sae=120mm of model of Z=5 razor blade, ap=5mm, vf=5000mm/min, life of Vc=1600m/min cutting tool: D=160mm of diameter of bit body of 170 finish machining, tine counts SPKT1504AZNae=120mm of model of Z=20 razor blade, ap=0.

2mm, vf=500mm/min, life of Vc=180m/min cutting tool: D=125mm of diameter of 100 bit body, tine counts SNMN0903ENSAe=100mm of model of Z=6 razor blade, ap=0.

2mm, vf=5000mm/min, life of Vc=1600m/min cutting tool: 600 from the watch 3 in knowable: When using plane of cylinder body of CBN300 milling casting pig, satisfy treatment requirement completely not only, and its production efficiency and cutting tool life all compare tower above of hard alloy cutting tool multiple. Life of low, cutting tool grows surface roughness of surface of the workpiece after cutting tool of 5 epilogue PCBN had efficient, tall wearability, treatment wait for good character, the treatment quality that applies PCBN cutting tool to be able to improve a product not only in milling treatment, and can raise treatment to manufacture efficiency substantially, contented and modern industry is efficient manufacturing need, have very good promotion value. CNC Milling CNC Machining