Development trend of polycrystalline cubic boron nitride (PCBN) applications
2018-10-11 15:01:32
Since the success of PCBN tools in the cutting practice of several difficult-to-machine materials in the mid-1970s, the world's advanced industrial countries have invested a lot of manpower and material resources to continuously carry out experimental research. Currently, countries are opening up new fields for the use of PCBN. Have:
1 For precision machining At present, specially ground PCBN tools are used on ultra-precision lathes with a cutting depth of 15 to 20 μm and a feed rate of 0.608 μm/r. =0.0254 μm. Cutting stainless steel on a general precision CNC lathe can achieve surface roughness within Rmax = 0.2 μm.
2 High-speed milling for cast iron has been applied in Japan, the United Kingdom and Germany, and has shown great advantages, mainly: high cutting speed, long service life and stability, compared with ceramic tools, improve service life 20 to 30 times, the dimensional accuracy of the workpiece during cutting is stable, the number of times of adjustment can be reduced, the surface finish of the machined surface is good, and the processing time of the next process such as honing can be shortened.
3 for rotating tools PCBN rotary tools such as Sumitoron reamer from Sumitomo Corporation of Japan and end mills and boring tools for mold and tool finishing and finishing. Since PCBN is a polymer with a thickness of 1.6 mm, the cemented carbide substrate must be soldered to the body during soldering, and can be used for PCBN drills and helical end mills.
4 finishing hardened gears
It is quite difficult to remove the quenching deformation of the spiral bevel gear. At present, it is common to use a pair of gears for grinding or manual or tooth-by-tooth correction, which not only takes a long time, but also has a pitch accuracy that is not ideal. The use of PCBN tools to machine hardened spiral bevel gears with a modulus of 7 can achieve pitch accuracy that cannot be achieved by grinding and manual grinding, and the combined transmission noise can be reduced by 2 to 8 decibels. Recently, PCBN tools have been used to process small gears with a modulus of 4, and good results have also been achieved.
5 cutting ceramics
Ceramic is a new generation of mechanical engineering materials after metal materials, but the processing of ceramics has been plagued by the metal cutting industry. At present, the diamond grinding wheel grinding process generally used has the disadvantages of low processing efficiency and high processing cost. The researchers in Japan used PCBN tools and plasma flames to heat the ceramics, and achieved good results. The processing efficiency was improved by 3 to 10 times, and the surface roughness of the workpiece was up to Ra 0.6 to 0.15 μm.
The high wear resistance of PCBN tools makes them particularly suitable for automation and controlled production. These production methods are the development trend of the world's mechanical processing industry. Therefore, the application of CBN tools is inevitable and has great development potential.
(1) The market demand has great potential.
(2) The update of working conditions such as machine tools has promoted the growth of PCBN tool applications.
(3) The characteristics of PCBN tools promote the use of growth. With the development of cutting speeds toward high and ultra-high speeds and the maturity of high-speed cutting processes, the use of PCBN tools will increase.
(4) From cost analysis. However, from the surface price point of view, PCBN tools seem to be more expensive than other tools, but the cost is reduced from the comprehensive analysis of reducing machine footprint, improving production efficiency, and avoiding tempering and hard processing. And with further scientific research, the manufacturing cost of PCBN tools is reduced, and the performance update will benefit users.
China has become a major producer in the world in the production of superhard materials such as diamond and CBN. CBN abrasive preparation, Henan has become the main base, Zhengzhou High-tech Zone Fenike and Nanyang Zhongnan Optical Instrument Factory, all of which are mass-produced and exported. However, domestic difficult-to-machine materials mainly rely on the import of tools and abrasive tools from GE, Sumitomo, and Showa Denko. South Korea has a fast research in this field. Henan Province has a leading position in CBN abrasive production and research. It is urgent to carry out research on CBN products and solve its key technologies and industrial production. The domestic market should be occupied as soon as possible to form a major production base.
In short, tool materials have been constantly updated and developed, and there is no end to it. There are also many scientific research departments in China that are stepping up the development of new PCBN composite sheets and PCBN polymers. The performance difference between PCBN tools and foreign countries is also shrinking. It is believed that in the near future, the development of PCBN tool applications in China will definitely be brought forward.
1 For precision machining At present, specially ground PCBN tools are used on ultra-precision lathes with a cutting depth of 15 to 20 μm and a feed rate of 0.608 μm/r. =0.0254 μm. Cutting stainless steel on a general precision CNC lathe can achieve surface roughness within Rmax = 0.2 μm.
2 High-speed milling for cast iron has been applied in Japan, the United Kingdom and Germany, and has shown great advantages, mainly: high cutting speed, long service life and stability, compared with ceramic tools, improve service life 20 to 30 times, the dimensional accuracy of the workpiece during cutting is stable, the number of times of adjustment can be reduced, the surface finish of the machined surface is good, and the processing time of the next process such as honing can be shortened.
3 for rotating tools PCBN rotary tools such as Sumitoron reamer from Sumitomo Corporation of Japan and end mills and boring tools for mold and tool finishing and finishing. Since PCBN is a polymer with a thickness of 1.6 mm, the cemented carbide substrate must be soldered to the body during soldering, and can be used for PCBN drills and helical end mills.
4 finishing hardened gears
It is quite difficult to remove the quenching deformation of the spiral bevel gear. At present, it is common to use a pair of gears for grinding or manual or tooth-by-tooth correction, which not only takes a long time, but also has a pitch accuracy that is not ideal. The use of PCBN tools to machine hardened spiral bevel gears with a modulus of 7 can achieve pitch accuracy that cannot be achieved by grinding and manual grinding, and the combined transmission noise can be reduced by 2 to 8 decibels. Recently, PCBN tools have been used to process small gears with a modulus of 4, and good results have also been achieved.
5 cutting ceramics
Ceramic is a new generation of mechanical engineering materials after metal materials, but the processing of ceramics has been plagued by the metal cutting industry. At present, the diamond grinding wheel grinding process generally used has the disadvantages of low processing efficiency and high processing cost. The researchers in Japan used PCBN tools and plasma flames to heat the ceramics, and achieved good results. The processing efficiency was improved by 3 to 10 times, and the surface roughness of the workpiece was up to Ra 0.6 to 0.15 μm.
The high wear resistance of PCBN tools makes them particularly suitable for automation and controlled production. These production methods are the development trend of the world's mechanical processing industry. Therefore, the application of CBN tools is inevitable and has great development potential.
(1) The market demand has great potential.
(2) The update of working conditions such as machine tools has promoted the growth of PCBN tool applications.
(3) The characteristics of PCBN tools promote the use of growth. With the development of cutting speeds toward high and ultra-high speeds and the maturity of high-speed cutting processes, the use of PCBN tools will increase.
(4) From cost analysis. However, from the surface price point of view, PCBN tools seem to be more expensive than other tools, but the cost is reduced from the comprehensive analysis of reducing machine footprint, improving production efficiency, and avoiding tempering and hard processing. And with further scientific research, the manufacturing cost of PCBN tools is reduced, and the performance update will benefit users.
China has become a major producer in the world in the production of superhard materials such as diamond and CBN. CBN abrasive preparation, Henan has become the main base, Zhengzhou High-tech Zone Fenike and Nanyang Zhongnan Optical Instrument Factory, all of which are mass-produced and exported. However, domestic difficult-to-machine materials mainly rely on the import of tools and abrasive tools from GE, Sumitomo, and Showa Denko. South Korea has a fast research in this field. Henan Province has a leading position in CBN abrasive production and research. It is urgent to carry out research on CBN products and solve its key technologies and industrial production. The domestic market should be occupied as soon as possible to form a major production base.
In short, tool materials have been constantly updated and developed, and there is no end to it. There are also many scientific research departments in China that are stepping up the development of new PCBN composite sheets and PCBN polymers. The performance difference between PCBN tools and foreign countries is also shrinking. It is believed that in the near future, the development of PCBN tool applications in China will definitely be brought forward.
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