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CBN PCD inserts are designed with cubic boron nitride and polycrystalline diamond. Thus, these cutting tools are hard enough to work on different types of steel and titanium alloys most efficiently.
CBN Inserts
CBN cutting tools have broad applications in hard steel cutting. First, CBN is synthetic, hence perfect in cutting hardened steels, which are PCD unsuitable for cutting because of their brittleness. CBN has stability and wear resistance; thus, CBN cutting tools maintain their sharpness even after extensive use.
PCD Inserts
PCD cutting inserts are ideal for non-ferrous materials, such as aluminium and copper. Also, polycrystalline diamond is a cutting material suitable for soft materials because it provides a fine and smooth finish. PCD is applicable in making PCD cutting tools and cares for its brittleness when cutting hard materials.
Combined CBN PCD Inserts
A combined CBN PCD insert incorporates the benefits of both CBN and PCD. These inserts excel at cutting challenging materials, giving longevity and precision.
CBN Inserts for Steel Machining
CBN inserts are ideal for steel machining, especially hardened steel. They are applicable for finishing and roughing operations due to their hardness and thermal stability.
PCD Inserts for Aluminium Machining
PCD inserts are friendly to aluminium machining and their alloys. They are better used in operations like turning, milling, and drilling due to their non-stick and wear-resistant properties.
Automotive Industry
CBN inserts are widely used in the automotive industry to machine hardened steel components such as camshafts, crankshafts, and gears. Also, PCD inserts are used to machine aluminium engine blocks, cylinder heads, and wheels, which improve strength and precision of these parts.
Aerospace Industry
CBN and PCD inserts are pivotal in the manufacture of critical components in the aerospace industry. The hardness and durability of PCD tool inserts ensure they withstand premium machining standards required for parts such as turbine blades and housings made from composite materials and aluminium.
Machinery and Equipment Manufacturing
CBN cutting inserts
are used to machine precision gears and shafts in machinery and equipment manufacturing. PCD inserts enable the production of complex shapes in composite materials used in machine components.Tool and Die Making
CBN and PCD inserts are used to make tough cutting tools and dies in this industry. Their longevity minimizes tool wear; thus, this efficiency reduces maintenance costs in the industry.
Medical Device Manufacturing
In the medical device industry, CBN and PCD inserts make precision components, such as surgical implants and instruments, made from difficult materials like titanium and hard alloys. Their precision guarantees reliability in sensitive medical applications.
Electronics Industry
CBN and PCD inserts manufacture components like heat sinks and casings out of composite materials and copper. Their non-abrasive properties give them the ability to provide smooth finishes essential for electronics functioning.
Aviation & Defense
The rigorous standards of the aviation and defence sectors demand precision. Industries rely on CBN and PCD inserts to create critical components such as missile guidance systems and aircraft casings while ensuring safety and reliability.
Energy Sector
The energy sector commonly deals with tough materials. CBN and PCD inserts are ideal for machining parts of generators, turbines, and downhole tools in the oil and gas industry, offering efficiency, longevity, and lower maintenance costs.
These cutting tool inserts have been designed with specific requirements, making them very suitable for industrial cutting needs.
Materials
CBN is known for its hardness and thermal stability. That is why it is ideal for cutting hardened steel. PCD, on the other hand, offers excellent cutting edges. It is suitable for machining soft and non-ferrous metals like aluminium.
Geometric Features
CBN PCD inserts come in various shapes and sizes suitable for machining operations. These geometric features are critical for ensuring effective and accurate cutting. These inserts are designed with sharp edges for precise cutting and minimising cutting force. They come with multiple sides, thus allowing prolonged use before replacement is needed.
Proper installation of CBN PCD inserts ensures they operate effectively and safely. Below are some steps for installing these cutting tool inserts:
Safety first
Turn off the machine and unplug it from the power source to prevent accidents. Wear protective gloves and safety goggles when handling cutting tools and inserts.
Remove the Old Insert
Using tools like a wrench, remove the clamp or screw holding the old insert in place. Take out the old insert from the tool holder.
Clean the Tool Holder
Use a clean cloth to remove any debris, dust, or residue from the tool holder's pocket. This new CBN PCD insert must be securely placed in the pocket of the tool holder.
Position the Insert
The tool holder pocket should be attached to the CBN PCD insert. Ensure that the insert is oriented in the correct direction by checking the alignment key or notch.
Secure the Insert
PNCD; CBN: PCD inserts must be tightly secured in the holder's pocket with a clamp or screw. They should be firmly tightened to hold the insert in place without movement.
Reattach the Tool Holder
After securing the insert, reattach the tool holder to the machine. Check to ensure it's securely fastened.
Testing the Installation
After installing the CBN PCD insert, slowly turn the machine on at a low speed. This allows for checking the stability of the insert and ensures no vibrations or movements.
The CBN inserts should always be maintained to help enhance their longevity and performance.
Regular Inspection
Check the inserts regularly for wear, chipping, or cracking. Close observation will help determine when a CBN Pcd insert needs to be replaced.
Cleaning the Inserts
Clean them after every use. Use a soft brush or cloth to remove the particles. Avoid using harsh chemicals that could damage the cutting edge.
Sharpening
Consider having a professional sharpen these inserts or follow the manufacturer's guidelines for sharpening them at home. Use a diamond wheel for sharpening.
Proper Storage
Store them in a dry, cool place, away from direct sunlight. This prevents damage when not used.
Replacement
Always ensure that worn-out inserts are replaced when due. Continued use of a worn-out insert may damage the tool holder.
Choosing suitable CBN and PCD inserts is a critical decision and depends on the type of material to be cut and the machining operation used.
Material Compatibility
CBN inserts are ideal for machining hardened steels like alloy steel, tool steel, and hard alloys. The CBN cutting edge maintains its sharpness with reduced wear over time. These properties make CBN the preferred choice for the automotive and aerospace industries, which commonly machine these materials.
Machining Operation
PCD inserts are designed for precision machining operations. Such operations include turning, milling, and drilling non-ferrous materials like aluminium, copper, and composites. PCD offers a smooth and accurate finish that enhances the quality of these materials and makes it suitable for the electronics and medical device industries.
Insert Geometry
Cuts with positive rake reduce cutting resistance, suitable for softer materials. Negative rake edges have great control over the chip and are better for hard materials. Select an insert carbide geometry based on the specific requirements of the machining task.
Industrial Requirements
Consider the longevity of the inserts when choosing PCD and CBN. PCD inserts are suitable for production industries that require high accuracy and large volumes, while CBNs are ideal for industries handling tough materials.
Inserts have a longevity of around 12 months or one year with good maintenance. When used in tough machining contexts, they should be replaced more frequently than that.
The two types of inserts are made for individual uses. PCD inserts, particularly, are delicate due to their brittleness; thus, they can only be used once. Tough CBN inserts can be resharmened a few times, though they have to be replaced eventually.
CBN inserts work optimally for hardened aluminium, though PCD inserts are more suitable for machining aluminium due to their efficiency. CBN is valuable for Hard- to-machine Aluminium that requires extra strength and durability.
Store them in a dry and cool area away from a direct source of sunlight. Protective cases or boxes are suitable for preventing such inserts from smashing or breaking. Avoid exposing the inserts to moisture or humidity to prevent them from rusting.
