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ZhengzhouHalnnSuperhardMaterialsCo.,Ltd

MachiningCharacteristicsofLargescalerolls andthecommoncuttingproblems 1 2 3 4 Contents ApplicationCaseForLargescalerolls ApplicationCaseForTungstenCarbideRolls 5 CBNandPCDInsertsForRollsMachining RecommendCuttingParameterswithHalnnTools

CharacteristicsofHeavyturning

CharacteristicsofHeavy-dutyTurning:(1)Largesize(2)HeavyWeight

Comparewithcommoncutting,heavy-dutycuttingtoolhasthecharacteristicsoflargecutting depth,relativelylowcuttingspeedandrelatively slowfeeds,soitsprocessingtechnologyisvery differentfromordinarymechanicalcuttingprocess. TheseprocessesCharacteristicsexistintherigidity ofthemachine,reducingthestabilityoftheperfor -mance,thechoiceoftools,toolinstallation,the choiceofcuttingcondition,workpiececlampingand others;especiallyprocessinghighhardnessheavy partsismostdifficult.

Commonquestionsofmachiningheavy-dutycomponent

CommonQuestions:

(1)Itneedslongtimemachiningeachcomponent, andneedchangetheinsertintheprocesswhichwill affecttheprocessefficiency. (2)Highhardnesscastingsexistsand,stomach,white hardpot,ectdefects,whichleadtotheinsertchipping ordamage. (3)Afteraddingmaterials(Spraying,Surfacingor lasercladding),thecomponentsurfacehardnessis high,whichmakeitmoredifficulttomachine,such aslasercladdingmold,sprayingtolls,ect. (4)Largescalecomponentitselfhashighhardness, suchaswindpowerbearings,heavyGears,high hardnessmetallurgyrolls,largescalewearresistant component

Largescalecastings:highNi-Crcastiron,highchromiumcastironitself hardnesswillachieveHRC60,andthesurfacewillhavesand,which willleadtodifficulttomachine.

Highhardnesscoldrolls

RollsCommonCuttingTypes RoughingCylindrical HoleTurning Milling RollRepairing TurningGroove HeavyTurning

1.Lowhardnessrollsprocessingcharacteristicsandtoolselection Suchasductileironroll,highalloycastironroll,theycommonly usedinhotroll,Supportingroller,middleroller.Comparewith workingrolls,theircharacteristicsarelowhardness. Turningthistyperolls,youcanchoosecarbideinsert. 2.Processingcharacteristicsofhighhardnessrollsandtoolselection Suchasmachiningchilledcastiron(ICDP),Highnickelchromium castironrolls,highboronsteelrolls,HSSRolls,Semi-steelrolls (castingsemi-steelrollsandhighcarbonsemi-steelrolls),Ni-Cr-Mocentrifugalcompositerolls. Becauseofitshighhardness,theserollsblankusuallyhasstomatal,sand,ectdefects.Anditrequireshighon thecuttingtoolsperformance,suchasimpactresistance,heat-resistance,wearresistance,ect.

Rollclassificationandcommonprocessingdifficulties Accordingtothelevelofhardnessclassification

HalnnCBNGradeForMachiningRolls ThepredecessorofHalnnSuperhardMaterialCo.,LtdisHenanSuperhardMaterialInstitutewhichis theearliesttomakeresearchonprocessingthebrittleandhardmaterialswithcubicboronnitride toolsandHigh-GradeDiamondTools.AsthepioneerofIndustrytoolsinChina,Halnnadheretothe initialbusinessphilosophyof"Notseekinglargeandcomplete,onlyinsisthigh-precisionand professional".Withmorethan10yearsexperience,Halnnhasresearchedonebyonenewmaterials grade,newtechnologyandbecomethemostfamouscuttingtoolsbrandinsuperhardcuttingtools industry.Specificabovecastingdefectsandotherproblems,Halnnreserachedsomecbngradesfor machiningthesehighhardnessrolls InsertGrade BN-K1 BN-S10 BN-S20 BN-S200 BN-S300

Howtoconfirmthetoolsolutions ComponentInformation Rolls Materials CuttingType □Roughing□Semi-finishing □Finishing Rolls Hardness CuttingCondition □Continuous□Semi-interrupt □HeavyInterrupt PreviousCuttingToolsInformation Insert Brand InsertModel Insert Materials ToolHolderModel Failure Mode Howcanyougetthetoolsolutionsformachiningrollsfromus? Pleaseoffertheinformationdetailsasthefollowingtablet:

RoughmachiningHighNi-CrAlloyCastIronRolls Material:HighNi-CrCastIron,Hardness HSD80 SelectedInsert:BN-K1 CuttingCondition:ap=9mm, Fr=0.5mm/r,Vc=25m/min SelectedInsert Efficiency HalnnBN-K1Improved3times CarbideInsert /

BN-K1:NormalWear,itcanuse allcuttingedges. BN OtherCBN:Insertfragmented,it leadtoseriousloss. FailureModeComparision BN-K1 OtherCBN

Semi-finishingchilledcastironrolls Material:Chilledcastironrolls,HardnessHSD67 SelectedInsert:BN-K1 CuttingCondition:ap=2mm, Fr=0.5mm/r,Vc=66m/min SelectedInsertEfficiencyLifetime HalnnBN-K1Improved2times3times CarbideInsert / / BN-K1 BN-K1

Finishturningforgedsteelcoldrolls Material:Forgedsteelcoldrolls,Hardness HRC60 SelectedInsert:BN-20 InsertmaterialEfficiency HalnnBN-S20Improved5 times CarbideInsert / BNS20

TurningthehighboronsteelrollsGroove Material:HighBoronSteel, HardnessHSD68 SelectedInsert:HLCBN InsertmaterialMachining Effect HalnnHLCBN24holes/insert

Intheuseofmetallurgicalrolls,whetheritiswirebarrolls,profilerolls,narrowstriprolls,striprolls, etc.,therewillbedefectssuchaswear,deformationandcrackingoftheworkingsurface.Thereareevendefects suchaspeelingoffthebody,fallingoff,andchipping.Therefore, hasbecomeaprojectonthe rollinglineinsteelcompanies. Withtheadvancementofsteelrolling,thewearresistanceoftherollsisbecominghigherandhigher, whichmakesitdifficulttoprocessandrepairtherolls.Inparticular,casthigh-speedsteel(HSS)rollsarea highlywear-resistantrolldevelopedinrecentyearsbecauseofitshighhardness,highwearresistance,good thermalhardnessandgoodtoughness.Therefore,moreandmorepeoplepayattentiontoit.However,therepair afteritsusehasalwaysbeenaproblem. Thedifficultyofcuttingalsorestrictstheapplicationanddevelopmentofhigh-speedsteelrolls.People havebeenpursuingandsearchingforatoolthatismoresuitableforhigh-speedsteelrollcutting. EarlyTimes，themanufacturerusecarbidetoolsandceramictools,whichcannotmeettheneedsofroll repairprocessingduetotheperformanceoftherolls,processingefficiency,processingaccuracy,etc.,.HALNN combinestheexperienceofalargenumberofsteelmillrepairrolls,andselectstheappropriateCBNgradefor differentrollrepairconditionstohelprollmillsandsteelmillsfactorysolveaseriesofsimilarproblems.The followingaresomeoftheexamplesoftherepairrollindustry. RepairingRolls

TurningtherepairingThreadedsteelroll BNS20BNS10 Material:HighSpeedSteelrolls,HardnessHRC60 SelectedInsert:BN-S20/BN-K1 MachiningCondition: Vc=25m/min,ap=0.5mm，f=0.5mm/r Insertmaterial Efficiency HalnnBN-S20 5times CarbideInsert / Note：Whenreparingthegrooves,belongtoheavyinterruptturningcondition,whichwillrequire theinsertshightoughness,FirstChooseBN-K1,SecondBN-S20

TurningRepairedHSSRolls TurningrepairedHSSRolls Material:HighSpeedSteelrolls,HardnessHRC63 SelectedInsert：BN-S300（Therollsneedhave goodsurface） MachiningCondition:Vc=26m/min，ap=2mm， f=0.5mm/r

§1SurfaceQuality TungstenCarbideInsertsMachining HalnnCBNInsertsMachining

SurfacequalityComparison

Materials:CastingHighSpeedSteel Hardness:HRC64 InsertMaterials:BN-S300Vc=40m/min, ap=0.5mm，f=0.5mm/r TurningRepairedCastingHSSRolls TurningRepairedCastingHSSRolls Note:Asourexperience,Iftherepqiredrollssurfacequalityisgood,wecanchooseBN-S300,Ifit hassomecracks,drops,wecanchooseBN-S20,ifthesurfacequalityisterriblebad,wecan chooseBN-K1.

TungstenCarbideringisalsocalledtungstencarbide(WC)alloyrollring.Its hardnesscanreachHRA78~95atroomtemperature. Thecoldworkingmethodsofcementedcarbiderollsaremainlyand crescent(etchingribs),. Thetoolsusedforcarbideprocessingrollare .Normally,PCBN isgenerallyusedforroughturningcarbiderollswhichhardness≤HRA88.PCDTools aremostlyusedforfinishturningcylinder,chamferingandengraving. TurningTungstenCarbideRings

BN-S300belongtosolidcbn, onlyrecommendtoturning tungstencarbideringswhich hardnsiswithinHRC88, othersadvise Materials:TungstenCarbidweRings； Hardness:HRA88 InsertsMaterials:BN-S300 CuttingParameters: Vc=15m/min,ap=1mm,f=0.3mm/r CBNInsertsTurningTCRings CBNTurningTungstenCarbideRings

PCDInsertsTurningTCRings Materials:WC(TungstenCarbideRings）； Hardness:HRA88InsertMaterisl: ； (ForsomelargescaleTCrings,hardturning willperformmuchbetterthangrinding. PCDTurningTungstenCarbideRings

PCDNotchingToolsMillingTCRings

MillingTCRingsGrooves

EngravingLettersonTCRings

CVDToolsEngravinglettersonTCRings

CommonModelsFor RollsMachining 04

ToolHolderforPCDNotchingTools StructureImage OrderNo. Dimension(mm) D1D2D3L1L2 N4 42164.0635 N6 4.52.5165.2235 N8 53165.537 N9 6316637 N10 63.2166.841 N127.3416856 N13 84.516956 N148.85169.556 N1610.45181165 N18126181265 N2013.56181465 N2215.26201666

SpecificationofPCDNotchingtools Drawing OrderNo. Dimension(mm) ProductImage φD c L α φ2*0.4*4.06*80°2.00.4 4.06 80 φ2.5*0.5*5.2*80°2.50.5 5.20 80 φ3.0*0.6*5.5*80°3.00.6 5.50 80 φ3.2*0.6*6.2*85°3.20.6 6.20 85 φ4.0*0.6*7.53*80°4.00.6 7.53 80 φ4.0*0.7*7.83*70°4.00.7 7.83 70 φ4.0*0.8*9.55*80°4.00.8 9.55 80 φ4.0*0.7*7.98*80°4.00.7 7.98 80 φ4.0*0.8*9.68*80°4.00.8 9.68 80 φ4.0*0.9*10.8*80°4.00.910.80 80 φ5.0*0.7*7.5*80°5.00.7 7.5 80.0 φ6.0*0.9*9.0*80°6.00.8 9.0 80.0 φ7.0*0.8*11.0*80°7.00.8 11.0 80.0 φ8.0*0.8*12.0*80°8.00.8 12.0 80.0

OrderNo.Materials Shank Diamter/ d1h7 Total Length/ L Angle/ Er Tap/ Width B Product Image φ6.0*50*70°*0.3CVD 6 50 70 0.3 φ6.0*50*70°*0.5CVD 6 50 70 0.5 φ6.0*50*90°*0.3CVD 6 50 90 0.3 φ6.0*50*90°*0.5CVD 6 50 90 0.5 φ8.0*50*70°*0.3CVD 8 50 70 0.3 φ8.0*50*70°*0.5CVD 8 50 70 0.5 φ8.0*50*90°*0.3CVD 8 50 90 0.3 φ8.0*50*90°*0.5CVD 8 50 90 0.5 SpecificationofCVDEngravingTools CommonSpecification： φ6.0*50*70°*0.3 φ8*50*70°*0.5/0.6 CuttingParametersasour experience：2800RPM； =0.5-1.0； dependonthe customers'needs,itshould beassmallaspossible whentherollshardnessis higher.

3TypesCommonRolls

1.CBNInsertsandToolsHolderforrollswhichproducingplatesteel

CommonModelRNMN,CorrespondingToolHolderCRGNR/L

2.CBNInsertsandToolsHolderforrollswhichproducingwireballsteel

RNMNInserts,CorrespondingToolHolderCRDNN

3.CBNInsertsandToolsHolderforrollswhichproducingProfilesteel

No.RollsMaterials Wokringlayer hardness Recommendcuttingparameters 1HighChromeNickel CastIron HSD72-82 Roughing Vc=15-30m/min,ap=3-7mm,f=1-2.5mm/r Semi-finishing Vc=20-40m/min,ap=4mm,f=1.5-2.5mm/r 2HighChromeCastIron HSD72-78 Roughing Vc=10-20m/min,ap=3-7mm,f=0.50-1.2mm/r Semi-finishing Vc=15-30m/minap=4mmf=1.5-2.5mm/r 3 CastingHSS HSD82-90 Vc=5-15m/minap=3-8mmf=1-2.5mm/r 4 CastingSemi-steel HSD55-65 Vc=30-60m/minap=4mmf=1.5-2.5mm/r 5HighCartonSemi-Steel HSD65-72 Vc=25-50m/minap=4mmf=1.5-2.5mm/r 6 ChilledCastIron HSD50-70 Vc=25-50m/minap=4mmf=1.5-2.5mm/r 7HighChromeCastSteel HSD68-75 Vc=20-45m/minap=4mmf=1.5-2.5mm/r 8TungstenCarbideRings HRA88 Vc=15-60m/minap=0.2-0.5mmf=0.1-1mm/r 9 Forging9Cr2Mo HSD92-105 Vc=10-25m/minap=1mmf=0.5-1.2mm/r HalnnrecommendCuttingParameters

TypicalCustomsofHalnninrollsindustry pFinalCustomers：WISCO，ANSTELL，HBISSTEELGROUP,VALIN STEEL,BLHI，andBAOSTEELROLL. pCustomersforCarbideRings:XIAMENGOLDENEGRETSPECIALALLOY,ect. pCooperationcompany:QiqiharHeavyCNCequipmentLimited,Qinghaihuading heavy-dutymachinetools,ect.

HalnnSuperhard,asthepioneerofsuperhardcuttingtoolsin China,makenationalSuperhardMaterialsKeyLaboratory andHenanUniversityofScienceandtechnologyastechnical support,haveourownresearchcenter,focuson ,haveobviousadvantagesonmost industries,suchas ect.Atthesametime,wehavelaunchedaseries ofnewcbn/pcdcuttingtoolsandothermaterialtoolsin3C, aerospaceandNuclearenergymilitaryfield,dependingonth researchcenterofHenanSuperhardMaterialsInstitute.Our customershavecoveredmanycountriesandareas,including ChinaMainland,German,Italy,USA,Koreaandotherareas.

ZhengzhouHalnnSuperhardMaterialsCo.,Ltd

Superhardtoollocalizationpioneer, Professionalhardmaterialsprocessingtoolsleader!