Hard turning parts cutting tools and technology can effectively reduce processing time

In recent years, the unknown surface integrity of hard-turned parts has also caused some reluctance to use hard turning as the finishing of critical surfaces. However, recent developments in tool technology are likely to challenge these concepts. In particular, the new integral PCBN inserts and the new inserting technology have been proven to achieve accuracy equivalent to or better than the traditional grinding process.

One of the recent developments is the monolithic PCBN inserts, which are economical choices for hard turning, such as Seco CBN100 and CBN300. The integral inserts CBN100 and CBN300, especially for hardened steel processing, provide the same number of cutting edges as traditional inserts or carbide inserts, plus a longer cutting edge. Due to their overall structure, the new blades offer significantly higher wear resistance and lower cost per blade.

In a study comparing Seco's integral blades with toothed blades produced by five other tool manufacturers, the cost savings per blade ranged from 25% to 208%. (Guide: The correct use of polycrystalline diamond tools in cutting)

As an added advantage, CBN100 and CBN300 also make it possible to plug in cars. Plunge turning is a high-productivity form of hard turning that uses the entire cutting edge or part of the cutting edge to create a right-angle cut. This relatively new process has been proven to reduce machining time by as much as 90%, and the surface integrity of the produced parts is the same as those of the ground. With integral PCBN blades, these stress patterns remain constant, even in mass production.

In a test to examine the physical characteristics of 250 plunger parts, it was found that the residual stress was significantly lower than the stress caused by grinding. The quality of the part is also affected by the distribution of tangential residual stress. In the 250 parts tested in addition, both grinding and plunge-cutting produced tensile residual stress on the surface, but the thickness of the affected zone on the plunge-cutting parts was obviously thinner. Greater flexibility, faster tool change and longer tool life have an effect on reducing processing costs, increasing productivity and better part quality, far exceeding the initial cost of PCBN tools.

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