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Abstract Green manufacturing revolves around the efficient use of energy and the development of sustainable energy sources. Superhard materials and tools play a crucial role in industrial processing, as their performance significantly impacts the production of green GDP. These materials offer high processing efficiency, superior quality, and low environmental impact, making them key players in reducing industrial energy consumption. Cutting tools are widely used across industries, and as machining technology advances, there's an increasing demand for tools that support greener, more sustainable practices. Beyond extending tool life, modern cutting tools must also minimize contamination during operation, with dry cutting being the preferred choice whenever possible. When cutting fluids are necessary, it's best to use only rust inhibitors without organic compounds, which greatly reduces recycling costs.
The diversity of cutting tools and their varying working conditions influence the selection of coatings. Unlike turning or drilling, milling cutters must account for intermittent impacts. Early coatings focused mainly on wear resistance, with hardness as the primary metric. Coatings like titanium nitride, while effective, have a high friction coefficient, leading to significant heat generation during machining. To prevent overheating and deformation—both of which can affect accuracy and reduce tool life—cutting fluids are commonly used. However, these fluids, especially those containing oil, pose serious environmental and regulatory challenges. Even eco-friendly fluids require special disposal once they mix with machine contaminants, becoming hazardous waste. Regulatory bodies such as the EPA strictly manage such waste, and many states classify it as dangerous if it contains oil or certain alloys.
To address these issues, there's a growing need for tools that don’t require cutting fluids while still meeting high-performance demands. This led to the development of superhard CBN (Cubic Boron Nitride) tools. Designed by Fu Nike Superhard Materials Co., Ltd., these PCBN tools eliminate the need for cutting fluids, enabling high-speed and high-efficiency machining. With hardness comparable to diamond, CBN tools maintain excellent red hardness even at temperatures up to 2000°C. Though more brittle than cemented carbide, they offer better thermal conductivity and chemical stability than ceramics, along with higher impact resistance and crack resistance. They can effectively cut hard metals on less rigid machines, making them ideal for difficult material applications.
In addition to their performance benefits, superhard tools like CBN grinding wheels also contribute to energy savings in green manufacturing. The market for superhard materials and eco-friendly tools is expanding rapidly. According to reports, China currently produces 400,000 units of superhard tools and PCBN cutting tools annually, with sales below $200 million. However, industry analyses suggest that the potential market for these tools could exceed $1.5 billion, indicating strong growth opportunities in the future.