CBN Inserts For Cast Iron Parts in Automotive industry
Zhengzhou Halnn Superhard Materials Co.Ltd
Characteristics of CBN Tools
The excellent performance of CBN tools: High hardness, high heat resistance, high chemical inertness.
● The high hardness of CBN Tool proved its excellent abrasive resistance.
● The high heat resistance of CBN Tool can meet the cutting condition of high speed and high temperature.
● The high chemical inertness proved that CBN Tool has high antioxidant, it will not be oxidized in 1000℃ ， and will not react with iron series metal in 1200 . And it can be used ℃ with high cutting speed, so that improved the processing efficiency.
● CBN Tools have good thermal conductivity, which can realse the heat near the insert tips, and help improve the precision of the workpiece.
● CBN Tools will have low coefficient of friction, which will make the cutting tools have excellent anti-sticking ability, and help improve the surface quality of the component.
Typical Application of Cast Iron Parts Typical Application of Cast Iron Parts Typical Component ： Brake Disc, Brake Drum (Roughing & Finishing) ； Engine flywheel (Roughing & Finishing) ； Boron cast iron engine cylinder liner (turning, boring, Grooving) ； Cast iron engine block and Cylinder head (High speed Milling) ； Gearbox housing(High speed Milling) ； Crankshaft, Camshaft (Roughing & Finishing) ； Pearlite ductile iron (High speed Cutting) Also used for hard turning white iron Materials ： Grey Iron China Grade: HT200,HT250,HT300,ect. Japan Grade: FC200FC250,FC300,ect German Grade: GG20,GG25,GG30,ect Ductile iron: China Grade:QT600-3,QT700-2,QT800-2 QT9002, Japan Grade:FCD500 FCD600 FCD700 FCD800, German Grade:GGG50 GGG60 GGG70 GGG80.
Halnn CBN Grade for cast iron CBN Grade Suited Materials Machining Type Typical Application BN-K1 Chilled Cast Iron High chrome cast iron High alloy cast iron Roughing Alloy cast iron rolls Slurry pump (Impurity pump) Abrasive resistant castings BN-S300 Grey Cast Iron Roughing Finising Brake Disc/Brake Drum Cast Iron Engine Cast Iron Gearbox Cast iron cylinder liner BN-K20 Grey Cast Iron Semi-finishing Finishing Brake Disc/Brake Drum Cast Iron Engine Cast Iron Gearbox BNK30 Grey Cast Iron Iron series alloy Semi-finishing Finishing Brake Disc/Brake Drum Cast Iron Engine Cast Iron Gearbox BN-K10 Grey Cast Iron Powder Metallurgy Finishing Valve seat ring Engine cylinder bore Powder metallurgy parts
Halnn CBN material properties for cast iron Halnn CBN material properties for cast iron CBN Grade Binder CBN Content （ % ） Granularity (μm) Hardness BN-S30 TiC 85 8~2 3100~3300 BN-S300 Al ， TiC 97 4~6 3400~3600 BN-K10 Ti ， Co 95 ≤2 3300~3500 BN-K20 TiC 95 2~4 3400~3600 BNK30 Si ， TiC 97 2~4 3400~3600
Halnn CBN Material Cutting Condition CBN Content Characteirstics CBN Grade Cutting Depth Cutting Condition High Content CBN BN-K1 1-10mm Interrupt turningContinuous turning BN-S30 1-10mm Semi-Interrupt turning BN-S300 ≤2mm Continuous turning BNK30 ≤1.5mm Continuous turning BN-K10 ≤0.5mm Continuous turning
Cutting Parameters for Reference Materials Process Cutting Parameters Recommend CBN Grade Cutting Speed Vc(m/min) Depth of Cut ap （ mm ） Feed Rate Fr （ mm/r ） Grey Iron Roughing 400-1200 1-10 0.2-1.0 BN-S30 ， BNS300 Finishing 600-2000 ≤1 0.05-0.3 BNK30 ， BNK10 ， BN-K20
High Speed Cutting Brake Disc
Solutions for machining Brake Disc Roughing Brake Disc: Common Insert Mateirals---BN-S300 Insert Model:CNMN120416 、 SNMN120712 、 CNMN120716 Finish turning brake disc: Common Insert Materials---BN-K20 or BNK30 Insert Model: SCGN0904 、 CNGA120408 、 VNGA120408 、 WNGA080408 、 TNGA160408 Noted: Both surface of the brake disc is parallel, the Parallelism is about 0.06. Noted: Both surface of the brake disc is parallel, the Parallelism is about 0.06.
Double-inserts performed at the same time
Processing parth of brake disc 1.
Processing parth of brake disc
Processing with one-sided Successively (as shown below)
2.
Brake disc Cutting Tool Path
Tool Path
Grey Cast Iron Application-Finish Machining Brake Disc Finish machining Brake Disc-1 Component: Brake Disc Materials: HT250 Hardness: HB210 Selected Insert ： BN-S300 C06 SCGN090412 Cutting Parameters: Vc=900m/min ap=0.3mm, f =0.25mm/r Roughness: Ra1.6 Cooling method: Cutting fluid The tool life with coating cbn improved about 30% !
Grey Iron Application-Finish turning Brake Disc Finish turning Brake disc-2 Component: Brake Disc Materials: HT250 Hardness: HB170~210 Selected Insert: BNK30 TNGA160408-6S Cutting Condition: Vc=1000m/min ap=0.3mm,f =0.2mm/r Tool Materials Cutting Speed Tool Life Halnn BNK30 1000 m/min 160 pieces/blade Other Brand CBN 800m/min 100 pieces/blade Tool Life improved 60% ！
Rough Machining Brake Disc Component: Brake Disc Materials: HT250 Hardness: HB170~210 Selected Insert: BN-S300 CNMN120712 Cutting Parameters: Vc=500 m/min ap=2mm, f =0.55mm/r Insert Materials Cutting Speed Tool Life/blade Efficiency Halnn BN-S300 500m/min 200 pieces Improved 1.8 times Carbide Insert 180m/min 30 pieces ---Grey Iron Application-Rough turning Brake Disc
Halnn CBN Insert with positioning pit 1.CBN Insert with positioning pit and through hole It will be easy for positioning, especially for profiling and high speed cutting.
Halnn Wiper PCBN Insert 2.Wiper PCBN Insert ： (1) With same feeds, wiper insert can obtain better surface quality (2) With same roughness requirements, wiper insert can use larger feeds, which can reduce the time on each component, improve the efficiency ； Noted: It is Not suitable for profiling; suitable for machine tools and workpieces with high rigidity.
Application with Halnn Wiper CBN insert
Halnn Coating PCBN Insert 3. Coating PCBN Insert ： The perfect combination of smooth coating and CBN base can achieve better cutting performance and improve machining accuracy and life. PCBN Performance with Coating PCBN Performance without Coating
Cutting Grooves of Brake Disc
Two types Grooving Insert for Brake Disc
Brazed PCBN Grooving Insert, the brazining layer is easily off, which will lead to waste, so it only suits for finishing process or expanding the grooves .
Halnn BN-S300, Solid cbn insert, can be used for both roughing and expanding the grooves.
Clipping method of Halnn BN-S300
Continuous Improved
BNK30
Grey Iron Application-rough turning brake drum Rough turning Brake Drum Component: Brake Drum Materials: HT250 Hardness: HB170~210 Selected Insert: BN-S300 CNMN120716 Cutting Parameters: Vc=380m/min ap=2.5mm,f =0.65mm/r CBN Grade Cutting Speed Tool Life Efficiency Halnn BN-S300 380 m/min 95 pieces Improved 1.5 times Coating Carbide insert 150m/min 15 pieces ----
Finish machining brake drum Component: Brake Drum Materials: FC250 Hardness: HB170~210 Selected Insert: BNK30 WNGA080408-6S Cutting Parameters: Vc=650 m/min ap=0.5mm, f =0.2mm/r CBN Grade Tool Life Roughness Halnn BNK30 120 pieces Ra1.6 Other Europe CBN 70 pieces Ra2.0 Grey Iron Application---finish machining brake drum
Brake Drum Cutting Tool Path CNGN120716钝角 CNGN120716锐角 CNGN120716锐角 CNGN120716锐角 Cutting tools type and path
Gray Iron Application-milling engine block Finish milling engine block Component: Engine Block Process: Finish Milling engine block surface Materials: FC250 Hardness: HB170~210 Selected Insert: BN-S300 SNEN090308 Cutting Parameters: Vc=1700 m/min ap=0.3mm, fz =0.12mm/r CBN Grade Feed Rate Tool Life/blade Halnn BN-S300 3670mm/min 85 pieces Other CBN 3670mm/min 80 pieces
Grey Iron Application---Diesel engine cylinder liner Materials: Boron cast iron, HB230-270 Selected Insert: BN-S300 SNMN120412 S02020, ap=0.5mm, f=0.5mm/r, dry cutting Material Cutting Speed Vc Efficiency Tool Life Coating Carbide Insert 480m/min 39 S /pieces 26 pieces Halnn BNS300 880m/min 21 S /pieces 100 pieces Processing efficiency improved about 1 times, and the tool life improved 4 times, it will be more economic with Halnn cbn insert.
Grooving Insert for Cylinder liner
CBN
PCD/PCBN Grooving Insert （ MGGNType ） Order Code Cutting Edges Dimension (mm) W r MGGN200-02 1 ， 2 2 0.2 MGGN300-02 1 ， 2 3 0.2 MGGN300-04 1 ， 2 3 0.4 MGGN300-08 1 ， 2 3 0.8 MGGN400-02 1 ， 2 4 0.2 MGGN400-04 1 ， 2 4 0.4 MGGN400-08 1 ， 2 4 0.8 MGGN500-02 1 ， 2 5 0.2 MGGN500-04 1 ， 2 5 0.4 MGGN500-08 1 ， 2 5 0.8 MGGN600-02 1 ， 2 6 0.2 MGGN600-04 1 ， 2 6 0.4 MGGN600-08 1 ， 2 6 0.8
PCD/PCBN Grooving Insert （ MRGN Type ） Order Code Cutting Edges Dimension （ mm ） W r MRGN200-R1.0 1 ， 2 2.0 1.0 MRGN00-R1.5 1 ， 2 3 1.5 MRGN400-R2.0 1 ， 2 4 2.0 MRGN500-R2.5 1 ， 2 5 2.5 MRGN600-R3.0 1 ， 2 6 3.0
Halnn Customized Service: PCD/PCBN Grooving Inserts and the corresponding tool holder, we can offer customized service for you, you may need offer the information in the following form: Insert Shape Item 内容 Blade Width W （ mm ） Blade Radius R （ mm ） Machining Materials Groove Depth H （ mm ） Machining Part □ Cylindrical Groove □ Internal Groove □ Endsurface Groove Tool Holder Length*Square （ mm ）
Component:Automotive crankshaft damping Materials:FC200, Hardness:HB220 Insert:BNK30 CNGA120408 S01020 Tungsten Carbide:Vc=300m/min,ap=0.5mm ， Halnn CBN:Vc=650m/min,ap=0.5mm ， Tool Life improved 11.5 tims, and the tool costs reduced about 35%! The efficiency of Halnn cbn insert will improve about 2 times than carbide insert,the tool costs reduce about 35%! Grey Iron application-Automotive Crankshaft damping
Grey Cast Iron application-Automotive clutch plate Selected Insert: CCGW09T304 S01025 BN-K20 Tool Life: 150 pieces/blade, The roughness and brightness of the component will be improved, and is suitable for machining castings.
New CBN Mateiral---BNK30
ASTM
CBN Tool material certified by EU and US
Material Society in China
New CBN Materail---BNK30 Application 1 Item Brake Disc Manufacturer Material GG25(FC250) Process Rough Machining Selected Insert BNK30 CNGN120716 Cutting Parameters Vc=950m/min,Fr=0.7mm/r, ap=2mm Machinin Type Dry Cutting With Same cutting parameters, the tool life BNK30 is about 1.45 times of other cbn insert.
New CBN Materail---BNK30 Application 2 Item Brake Disc Manufacturer Materials GC250 (HT250) Process Finishing, dry cutting Hardness HB180~HB220 Selected Insert CNGN120412 Testing Performance Insert Materails Halnn BNK30 Other International CBN Cutting Condition Vc=1150,Fr=0.2,ap=0.25 Vc=880,Fr=0.2,ap=0.25 Roughness Ra1.6 Ra1.6 Tool life 640 475 Tool life improve about 35% ! Efficiency improve about 30%!
Performance
CBN Inserts machining
with other CNC insert, Halnn cbn insert can realize high speed cutting and improve the process efficiency.
with coating carbide insert, the tool life can improve
times, the costs
7 times, cbn insert will be more economic. 3. The roughness can be improved with cbn insert.
Superhard, is one of the lead brand in China, not only can offer all ISO cutting tools, but also can offer customized service.
advantages of Halnn
cast iron 1.Comparing
2.Comparing
about 9~15
just about
4.Halnn
Product characteristics ：
About Halnn
Halnn Superhard, as the pioneer of superhard cutting tools in China, make national Superhard Materials Key Laboratory and Henan University of Science and technology as technical support, have our own research center, focus on cbn cutting tools and high grade diamond tools for machining brittle and hard materials, have obvious advantages on most industries, such as turning instead of grinding, high hardness materials machining, heavy turning, high speed machining, ect. At the same time, we have launched a series of new cbn/pcd cutting tools and other material tools in 3C, aerospace and Nuclear energy military field, depending on the research center of Henan Superhard Materials Institute. Our customers have covered many countries and areas, including China Mainland, German, Italy, USA, Korea and other areas.
Zhengzhou Halnn Superhard Materials Co.,Ltd Web: www.halnncbn.com, www.halnnpcd.com
Whatsapp:+86-18637133872 Email: yapu.f@hlcbn.com