Halnn journal
Hard turning: How to choose between ceramic and CBN inserts? Ceramic inserts and CBN inserts are widely used in manufacturing industry globally. CBN and ceramics are two kinds of cutting tool materials, but in terms of inorganic non-metallic materials, CBN (full name: Cubic Boron Nitride) and alumina, silicon oxide and other traditional ceramic tool materials collectively referred to as ceramic materials. So, in some applications, both ceramic tools and CBN tools are suitable. As a pioneer brand of applying CBN and ceramic tools in heavy-duty machining and hard turning, Halnn Superhard has always believed that ceramic inserts and CBN inserts belong to a symbiotic relationship, not an antagonistic relationship. Both of them, respectively, play their respective advantages to assist the rapid development of the manufacturing industry.
In terms of ceramic inserts, the common brands on the market are Sweden's Sandvik, Germany's SPK, Japan's NTK, the U.S. Green Leaf, Japan's Kyocera, China's Halnn, among which whisker toughened ceramic inserts are mainly used in the field of high-temperature alloys, silicon nitride ceramics are used in the machining of hard materials and cast iron, alumina ceramics are used for hard turning. All above applications are overlapped with CBN.（see next page）
Halnn journal Maker Grade
NTK Halnn
SPK
Kennametal
HC2 A100
SH1
KD9
HC4 A200 SH2/SH3 HC5
KY1615
Sandvik
LX21 CC650
A65 CEM6
MC2
HC7 ZC4
SH2C
ZC7
XD202
NB90M
XD805
N890S
KT66
KY4400
LX11
HTM85D
D100
SN60
AC5
D200
SN80
KD60
SL100
KY2000
SL200
KY3000
CC690
SX6
SL500 /SL50 6SL608
KY1320 /KY3500
CC6090
SX1
SL508
SX9
SL800 /51806
HC1
Tungaloy Greenleaf KYOCERA MITSUBISHI SUMITOMO
CC620
LXA
AN66 GEM9
SX8
D300
ceramic SX2
SX7
N100
SP2 H100 WA5 H200 WAI S100 S200
51550C
A75000
W80
SN60
KS5000
FX90 FX105
GSN
KY1525 KY4300 MC3
CC670
KS6000 KS7000
KY1540 CC6080 /KY1310 KY2100 CC6060/CC6065 CC1690
The main composed of Al2O3; white and pink in color, suitable for finishing and semi-finishing of cast iron parts.
NS130
KS5000
CX710 C5C73
KY2400
The main component of A12O3, used for high-speed finishing and semi-finishing of hardened steel and bearing steel, more wear-resistant, used for the finishing of high-hardness steel or the finishing and semi-finishing of ductile cast iron.
NB100C
HW2 EC1
Application
XD515 XD520
NS260 NS30
The main component silicon nitride, gray, for rough machining of cast iron steel and non-ferrous metals, good toughness.
KS6040 CXC73 IF110
HSN200
WG300 WG600 WG700
KX207
NS260C Turning and milling for machining high temperature alloys.
Halnn journal Ceramic inserts and CBN inserts, because of their high hardness and good wear resistance, are widely used in cast iron, rolls, bearings, hardened steel and other ferrous materials cutting. Generally speaking, for hardened steel precision hard cutting, PCBN is most applied; For non-precision hard cutting, ceramic and CBN inserts have a lot of overlaps in application, especially in roughing-finishing applications. The segment market of solid CBN is dominated by Chinese manufacturers, among which Halnn is the most famous one. For example: In cast iron field such as brake discs, brake drums, engine blocks and other gray cast iron automotive parts, ceramic inserts from SPK and Sandvik are popular. While, for high-efficiency production lines, customers are preferring solid CBN inserts from SECO or Halnn. In order to cope with the growing demands on specialization, scale and productivity, more and more far-sighted manufacturers noticed the advantages of CBN which are higher cutting speed and longer lifetime. Among these CBN inserts, BN-S300 series from Halnn is getting more and more acceptance because of its better performance and comprehensive use of cost. Followings are posters of Halnn from EMO exhibition from which we could see Halnn is providing solutions including machining methods for brake discs/drums sectors. Reducing the cycle time and increasing productivity by upgrading the inserts that is exactly what the end users need.
Halnn journal
Halnn journal
Rolling mill field:
Heavy duty hard cutting field such as wind turbine energy: Coexistence of ceramic and CBN inserts, the following content is extracted from SPK and halnn's introduction to this heavy duty hard cutting field, and some pictures are from the EMO exhibition, which are shared with you.
Halnn journal
Halnn journal
Finally, I would like to popularize the difference in physical properties between PCBN and ceramic inserts:
At the end of this article, I would like to share with you a case study comparing CBN and ceramic inserts, taken from Halnn's website. Hard turning ball screw ends： Workpiece material: CCr15 (hardness HRC60-62) Insert Model: BN-S20 CNGN120708 Cutting parameters: Vc=95m/min，Fr=0.10mm/r，ap=4.5mm
Halnn journal Processing method: dry cutting Tools Materials
Cutting Speed
Depth of cut
Failure mode
Halnn BN-S300 CBN inserts
95m/min
4.5mm
Normal wear
other brand ceramic inserts
65m/min
0.5mm
Damage rupture
Case of finishing boron cast iron Cylinder liner outer round: Machining process: Finishing cylindrical Workpiece material: boron cast iron Insert Model: BN-S300 SNMN120412 Cutting parameters: Vc=850m/min, Fr=0.25mm/r, ap=0.5mm Processing method: wet cutting Parameter comparison： Tools Materials
Cutting Speed
Halnn BN-S300 CBN inserts
850m/min
23 seconds/pcs
120 pcs/inserts
other European brand ceramic inserts
500m/min
40 seconds/pcs
25 pcs/inserts
Case of Finishing Brake Discs：
Workpiece: Brake Disc Material: GC250 (HT250) Hardness: HB210 Insert Type: BN-S300 CNMX120716(Positioning hole) Cutting parameters: Vc=800m/min, Fr=0.45mm/r
Machining beat Single edge life
Halnn journal Processing method: Semi-finishing, Dry Cutting Parameter comparison： Tools Materials
Cutting Speed
Feed Tools
life
Halnn BN-S300 CBN inserts
750m/min
0.55mm/r
1200pcs
other ceramic inserts
650m/min
0.35mm/r
420pcs
Email:halnntools@halnn-group.com WhatsAPP:15515925975