High Precision Cutting and High Speed Interrupted Cutting of Hardened Steel With PCBN Tools

1999 ◽  
Author(s):  
Katsuhito Yoshida ◽  
Satoru Kukino ◽  
Takashi Harada ◽  
Tomohiro Fukaya ◽  
Junichi Shiraishi ◽  
...  
Keyword(s):  
High Precision ◽  
High Speed ◽  
New Technologies ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Hardened Steel ◽  
Precision Machining ◽  
Polycrystalline Cubic Boron Nitride ◽  
Interrupted Cutting ◽  
Pcbn Tools

Abstract PCBN (Polycrystalline Cubic Boron Nitride) cutting tools have become very familiar in the industries for cutting hardened steel parts and the demand for PCBN tools is growing rapidly. One of the reasons for this is the trend of replacing grinding processes with cutting. Although the trend of processing is to use more cutting, there still remains grinding in many processing fields. High precision machining and high speed interrupted machining have been such fields. In this study it has been verified that a novel cutting method can be applied to high precision machining with the smoothness of Rz 0.8 μm and that a new PCBN has sufficient reliability against tool failure in high speed (< 250m/min) interrupted cutting. Thus cutting has become applicable to those machining and the trend of replacement of grinding with cutting will be enhanced. Those new technologies will be introduced in this report.

Development of Cutting Tools with Built-in Thin Film Thermocouple for Monitoring Machining Temperature

2011 ◽  
Vol 189-193 ◽  
pp. 3170-3174
Author(s):  
Qi Yong Zeng ◽  
Xiao Feng Zheng ◽  
Gao Hui Zhang ◽  
Le Chen
Keyword(s):  
Thin Film ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Vital Role ◽  
Polycrystalline Cubic Boron Nitride ◽  
Thin Film Thermocouple ◽  
Thin Film Thermocouples ◽  
Pcbn Tools ◽  
Deposition Conditions

Temperature plays a vital role in the machining industry today. NiCr/NiSi thin-film thermocouples have been deposited on the rake face of polycrystalline cubic boron nitride (PCBN) tools by magnetron sputtering. The typical deposition conditions are summarized. Static and dynamic calibrations of the NiCr/NiSi thin-film thermocouples are presented. The Seebeck coefficient of the TFTC is 37.3 μV/°C. The response time is about 3.9 ms. The testing results indicate that the developed NiCr/NiSi thin-film thermocouple sensors perform excellently when machining A3 steel in situ.

Research of Technology of Cutting Hardened Steel in HSM

2011 ◽  
Vol 338 ◽  
pp. 701-705
Author(s):  
Xiao Jun Zhu ◽  
Wen Sheng Xia
Keyword(s):  
High Speed ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Tool Material ◽  
Main Tool ◽  
Hardened Steel ◽  
Detection Methods ◽  
Tool Geometry ◽  
High Speed Milling ◽  
Coated Cemented Carbide

The key technology of the cutter that cutting hardened steel was researched by high speed milling machining method. At first ,three cutting elements of high speed milling machining was narratived, and we can obtain the principle of selection of parameters of cutting velocity, feed per tooth, longitudinal cutting depth and cutting width of axial, etc. With HSM ,we discussed the performance and selection points of tool material of coated cemented carbide, ceramic, cubic boron nitride , synthetic diamond and so on, and obtained the effect of the main tool geometry for the cutting process in HSM. The second, it analysised type and reason of damage of high speed cutting tools, and introduced three detection methods of tools. Finally, it was summarized and concluded.

New Pcbn for Heavy Interrupted Cutting of Hardened Steel

2007 ◽  
Vol 534-536 ◽  
pp. 1117-1120 ◽  
Author(s):  
Katsumi Okamura ◽  
Saturo Kukino ◽  
Tomohiro Fukaya
Keyword(s):  
High Precision ◽  
Tool Life ◽  
Hardened Steel ◽  
Main Process ◽  
Homogeneous Microstructure ◽  
Total Cost ◽  
Interrupted Cutting ◽  
Conventional Grinding ◽  
High Flexibility ◽  
Pcbn Tools

PCBN tools are used worldwide for machining of hardened steel parts in automotive industries. Because cutting by PCBN tools has many advantages, which are high-precision, highefficiency, high-flexibility and low total machining cost, compared with conventional grinding methods. But in heavy interrupted cutting of hardened steel, the tool life is not so stable by sudden breakage of the cutting edge, and total cost of cutting by PCBN is not so economical compared to the grinding. So the conventional grinding is still main process in such applications. Recently, demand for decreasing machining cost has grown in heavy interrupted cutting and much tougher PCBN material is required. To solve this problem, new PCBN has been developed. New PCBN has very fine and homogeneous microstructure to increase the toughness of sintered body that it provides a reliable tool life for heavy interrupted cutting. The features and cutting performances of new PCBN are described in this report.

scholarly journals PCBN Performance in High Speed Finishing Turning of Inconel 718

Metals ◽  
2018 ◽  
Vol 8 (8) ◽  
pp. 582 ◽  
Author(s):  
José Díaz-Álvarez ◽  
Víctor Criado ◽  
Henar Miguélez ◽  
José Cantero
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
High Speed ◽  
Cubic Boron Nitride ◽  
Hard Metal ◽  
Abrasive Tool ◽  
Polycrystalline Cubic Boron Nitride ◽  
Metal Tools ◽  
Pcbn Tools ◽  
Cutting Speeds

Inconel 718 is a Ni superalloy widely used in high responsibility components requiring excellent mechanical properties at high temperature and elevated corrosion resistance. Inconel 718 is a difficult to cut material due to the elevated temperature generated during cutting, its low thermal conductivity, and the strong abrasive tool wear during cutting process. Finishing operations should ensure surface integrity of the component commonly requiring the use of hard metal tools with sharp tool edges and moderate cutting speeds. Polycrystalline cubic boron nitride (PCBN) tools recently developed an enhanced toughness suitable for these final operations. This paper focuses on the study of PCBN tools performance in finishing turning of Inconel 718. Several inserts representative of different manufacturers were tested and compared to a reference carbide tool. The evolution of tool wear, surface roughness, and cutting forces was analyzed and discussed. PCBN tools demonstrated their suitability for finishing operations, presenting reasonable removal rates and surface quality.

PCBN Tool Performance Evaluation Based on Image Analysis of Machining Surface Texture

2007 ◽  
Vol 10-12 ◽  
pp. 762-766 ◽  
Author(s):  
P. Wang ◽  
D.L. Liu ◽  
Yi Zhi Liu ◽  
Xian Li Liu ◽  
Chun Ya Wu
Keyword(s):  
Surface Roughness ◽  
Image Analysis ◽  
Surface Texture ◽  
High Speed ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Polycrystalline Cubic Boron Nitride ◽  
Gray Histogram ◽  
Tool Performance ◽  
Conventional Detection

The Polycrystalline Cubic Boron Nitride (PCBN) cutting tools has have been developed for high speed machining in modern automation manufacture. The machining surface roughness is regarded as an important criterion to assess PCBN cutting tools performance. There are too many problems in conventional detection method. In order to solve that problem, we present a new way that is based on image analysis of machining surface texture to assess surface roughness. The new method is consisted of three steps. It captures surface texture image when machining is finished or pauses. Firstly, RGB histogram is adopted to analyze image pixel information. This means takes advantage of histogram technique and provides more pixel distribution information than gray histogram. Secondly, unsupervised texture segmentation is used based on resonance algorithm. Thirdly, a new estimation parameter E that is the density of surface contour peak is put forward to estimate machining surface roughness.

Using Pulse Laser Processing to Shape Cutting Edge of PcBN Tool for High-Precision Turning of Hardened Steel

2013 ◽  
Vol 7 (3) ◽  
pp. 337-344 ◽  
Author(s):  
Daisuke Suzuki ◽  
◽  
Fumihiro Itoigawa ◽  
Keiichi Kawata ◽  
Takashi Nakamura ◽  
...  
Keyword(s):  
High Precision ◽  
Laser Processing ◽  
Chemical Reactivity ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Surface Hardness ◽  
Hardened Steel ◽  
Cutting Edge ◽  
Precision Turning ◽  
Edge Sharpness

Polycrystalline Cubic Boron Nitride (PcBN) cutting tools have excellent characteristics, such as a high degree of hardness and low chemical reactivity, so they have the potential to replace the high precision grinding of hardened steel with high precision cutting. However, there are some problems inherent in so-called sintered materials, including low formability and unsteady wear. In order to solve these problems, pulsed laser processing is applied to shape a cutting edge. In this study, first PcBN cutting tools processed by lasers are adopted to the high-precision turning of hardened steel with 58HRC. As the result, these PcBN cutting tools provide a steady cutting state and a smoother finished surface. Second, in order to investigate these advantages of PcBN cutting tools processed by laser, individual requirements of the cutting tool are investigated: edge sharpness, surface quality including micro-defects, surface hardness, and friction coefficient. The results indicate that tools processed by laser have sharper edges and smoother, harder, and lowerfiction surfaces, compared to ground tools. Above all, the increase in surface hardness improves cutting performance because of it provides higher wear resistance.

The Application and Performance of Diamond and PCBN Tools in Difficult-to-Cut Materials

2017 ◽  
Vol 263 ◽  
pp. 90-96 ◽  
Author(s):  
Yu Hai Zhou
Keyword(s):  
High Speed ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Hard Material ◽  
High Speed Machining ◽  
Manufacturing Enterprises ◽  
Hard Materials ◽  
And Performance ◽  
Material Tool ◽  
Pcbn Tools

Diamondand PCBN are extra-hard materials. There are several grades in the PCD andPCBN groups. Comprehensive Review of Super hard materials such as diamond cutting tools, high-speed machining PCBN tool and performance, the type of domestic and international manufacturing and research status . Elaborate on three high-speed machining with a diamond cutter nature and characteristics of the domestic and foreign manufacturing enterprise status, as well as polycrystalline cubic boron nitride tool features and applications. The isotropic synthetic graphite high-speed processing of diamond tool applications, engine block, cylinder heads high-speed milling PCBN cutting tool applications, aerospace application example to illustrate the advantages of hard material tool in high-speed machining of titanium alloys in high speed turning PCBN tools. Hard material tool to provide guidance and support for the selection of high-speed processing manufacturing enterprises.

Metallurgical Study of Friction Stir Welded High Strength Steels for Shipbuilding

2014 ◽  
Vol 783-786 ◽  
pp. 2798-2803 ◽  
Author(s):  
Marion Allart ◽  
Alexandre Benoit ◽  
Pascal Paillard ◽  
Guillaume Rückert ◽  
Myriam Chargy
Keyword(s):  
Cubic Boron Nitride ◽  
High Strength Steels ◽  
High Strength ◽  
High Yield ◽  
Friction Stir ◽  
Polycrystalline Cubic Boron Nitride ◽  
Recent Developments ◽  
Metallurgical Study ◽  
Welding Processes ◽  
Pcbn Tools

Friction Stir Welding (FSW) is one of the most recent welding processes, invented in 1991 by The Welding Institute. Recent developments, mainly using polycrystalline cubic boron nitride (PCBN) tools, broaden the range of use of FSW to harder materials, like steels. Our study focused on the assembly of high yield strength steels for naval applications by FSW, and its consequences on the metallurgical properties. The main objectivewas to analyze the metallurgical transformations occurring during welding. Welding tests were conducted on three steels: 80HLES, S690QL and DH36. For each welded sample, macrographs, micrographs and micro-hardness maps were performed to characterize the variation of microstructures through the weld.

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