Development and Prospects of PCBN Tools in the 21st Century (5)

New developments in PCBN tools

With the development of blade manufacturing technology, domestic PCBN tools have made important progress, and the physical properties of the blades have undergone important changes. Both the price and the quality have revolutionized PCBN tools. The application of the new PCBN tool will certainly break the pattern that PCBN tools cannot be applied in the heavy-duty cutting field and intermittent cutting state.

(1) With the development of science and technology, people have improved the performance of PCBN tools through the following adjustments and improvements, and gradually expanded their application range.

(a) Improve the manufacturing process and reduce the manufacturing cost of PCBN. The binder phase material and its ratio to the hard phase are changed, the hard phase is reduced, and the binder phase is increased, so that the toughness and hot pressing efficiency of the PCBN are improved. The hardness of the new PCBN tool has reached HV3000~6000, which can rough the hard and brittle metal or non-metal, and the effect is very good.

(b) Improve the level of machine tools and promote the use of more expensive PCBN tools. Although the price of PCBN tools is slightly more expensive than that of cemented carbide tools, the increase in processing efficiency creates enough to compensate for the price factor. Figures show that tooling costs only 3% to 4% of manufacturing costs in modern processing, but it has a much greater impact on total manufacturing costs. Even if you reduce the price of the tool by 30% or increase the tool life by 50%, the total cost savings can be only about 1%, which can be said to be very small. If the tool price is increased by 50%, the processing efficiency is improved by 20%. This will reduce the total cost by about 15%. This ratio has a significant impact on manufacturing costs. Many companies spend huge sums of money to introduce high-efficiency machine tools, but use low-performance welding tools. Good horses are not equipped with good saddles. It is difficult to play the role of imported equipment, but it has caused more waste.

For the general SMEs, the grinding process of the finishing process is always the bottleneck of the manufacturing process. If you purchase a good lathe, use PCBN tools, and apply advanced cutting processes such as car grinding, you can save equipment investment and improve. Productivity can greatly increase the flexibility of the process. In addition, due to the increase in personnel costs and environmental protection requirements, it is also of great significance to promote the use of PCBN tools to fully utilize their potential performance and improve the level of cutting technology.

(2) In recent years, the application of PCBN tools has gradually increased, the most obvious being the processing of mud pumps in the metallurgical industry in the roll and automotive industry, as well as in the drilling engineering. Compared with the original cemented carbide and ceramic tools, PCBN tools have achieved satisfactory results. The cutting amount is shown in Table 1. It can be seen from the table that the improved cutting depth and feed amount are large, and the cutting speed is also high, and high processing efficiency can be obtained. In the past, such products were processed with hard alloys and ceramic turning tools, which have now been replaced by PCBN tools, which is a big step forward.

(3) In modern machinery manufacturing, ferrous metal processing is the highlight of machining. In recent years, the manufacturing process and comprehensive mechanical properties of PCBN tool materials have been greatly developed, which can effectively perform rough finishing of ferrous metals.

(4) The development of high technology and the popularization of automated processing technology have placed new demands on cutting efficiency and precision. At the same time, the application of various new wear-resistant and high-hardness materials in the industry is increasing, which requires the tool to have good physical, chemical and mechanical properties, and the three high characteristics of PCBN fully meet the requirements in this respect. Therefore, research on PCBN tools has great significance for the development of the machinery manufacturing industry.

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