Cubic boron nitride insert BN-K1 grade processing high alloy cast iron efficiency is remarkable

The so-called high-alloy cast iron is cast iron with special properties added to ordinary cast iron. The alloying elements usually added are silicon, manganese, phosphorus, nickel, chromium, molybdenum, copper, aluminum, boron, and the like. Common high alloy cast irons are: high chromium alloy cast iron, nickel hard cast iron (ie high nickel alloy cast iron or nickel chromium cast iron), anti-wear white cast iron with alloy composition. It is characterized by high hardness and good wear resistance. It is often used as wear-resistant alloy cast iron or wear-resistant alloy cast steel. It is widely used in machine manufacturing, metallurgical rolls, mining machinery wear parts, chemical desulfurization pumps, and high-chromium resistance in power equipment industry. Eclipse pump accessories, instrument industry and other departments. Most of the methods for processing such alloy castings are turning and milling. Due to high hardness and high brittleness, cutting becomes a problem. Choosing the right tool material directly affects the production efficiency, processing quality and production cost of processing high alloy cast iron materials. Proper selection of tool materials is critical.
With the continuous development of high-alloy cast iron materials, in order to achieve high efficiency and low-cost cutting, people have continuously researched and introduced three kinds of tool materials, such as cemented carbide tools, ceramic tools and cubic boron nitride tools, and become high-speed. Three main tools for cutting, dry cutting and hard cutting of high alloy cast iron.
The following is a processing analysis of high-alloy cast iron by cemented carbide tools, ceramic tools and cubic boron nitride tools.
1. Carbide tool processing of high alloy cast iron
For processing high chromium alloy cast iron, nickel hard cast iron (ie high nickel alloy cast iron or nickel chrome cast iron), high alloy cast iron such as anti-wear white cast iron with alloy composition, commonly used hard alloy tool grades are YG6, YG8, etc. The hardness of the cemented carbide body itself is in HRC71-HRC76, and the hardness of the high alloy cast iron is generally above HRC50. Therefore, when the high alloy cast iron is processed, the tool will not wear out, and the tool needs frequent tool change during the processing. If it is a small batch of small pieces or occasionally processing high-alloy cast iron, the carbide tool can be selected if the workpiece dimensional accuracy and surface roughness requirements can be met, and the machining time and blade replacement do not affect the overall processing economic benefit.
Second, ceramic tool processing high alloy cast iron
The machining of high-alloy cast iron carbide failed to solve the problem effectively, so ceramic tools were introduced after the cemented carbide tools. The hardness of the ceramic tool is higher than that of the cemented carbide tool and can withstand the high temperature of 2000 °C, so it has high temperature chemical stability, good wear resistance, small friction between the metal cutting tool and the metal, and it is not easy to produce built-up edge, and ceramic The main raw material of the tool is nitrogen and silicon, which are rich in nature. It can save a lot of important metals such as W, Co and Ta by using it instead of hard alloy. However, the biggest disadvantage is that it is brittle. In order to improve the toughness of ceramic tools, people have adopted Some elements are added to improve the impact toughness and fracture resistance of the ceramic tool. The order of the toughness of the ceramic tool is sequentially enhanced: alumina ceramic tool-composite alumina ceramic tool-Silicon Nitride ceramic tool. The toughness and strength of ceramic tools have been increased to a considerable extent, but they are still limited by their impact toughness, so they have been used in the field of precision machining and try to avoid intermittent cutting. During roughing, due to casting defects on the surface of large cast high alloy cast iron parts, the blade may be damaged during the processing of ceramic tools.
Third, cubic boron nitride tool processing high alloy cast iron
According to the above situation, people have developed cubic boron nitride cutters. Among the inorganic non-metallic materials, cubic boron nitride cutters also belong to one of ceramic materials, but the hardness of cubic boron nitride cutters is much higher than that of ceramic cutters. Due to its high hardness, it is called ultra-hard material with diamond. It has excellent high-temperature hardness. Although it is brittle than cemented carbide blades, its impact strength and crush resistance are significantly improved compared with ceramic tools.
At present, cubic boron nitride tools are the best tool materials for wear resistance in the field of ferrous metal processing. It has been demonstrated that the life of cubic boron nitride tools is generally several times to several tens of times that of cemented carbide blades and ceramic tools. Often used to process difficult-to-machine materials with hardness higher than HRC48. For example, China Hualing super-hard cubic boron nitride blade BN-K10 has achieved good results in the processing of high chromium alloy cast iron and nickel hard cast iron. It is characterized by high hardness, high wear resistance and excellent high temperature resistance. Improves machining efficiency and reduces machining costs compared to carbide tools. However, the BN-K10 grade (as shown below) belongs to the welded cubic boron nitride insert, so it is generally used for finishing, and the depth of the knife is below 0.3mm.

China Hualing Superhard is a Chinese national brand cutting tool enterprise integrating R&D, production, sales and service of cubic boron nitride tools (CBN tools). It has been committed to the complete tool products and design of high hardness cutting and high speed cutting. It is currently widely used in high hardness materials, high hardness workpieces after heat treatment, and other difficult-to-cut materials. He enjoys a high reputation in the academic field of superhard tools. As a pioneer in the localization of superhard tools, it is the most well-known tool brand in hard material processing and high-speed cutting.
With the continuous research of Valin super hard cubic boron nitride tool (CBN tool), the BN-K1 brand of integrated polycrystalline cubic boron nitride blade (pictured below) was finally developed, which is specially designed for high chromium alloy cast iron. Nickel hard cast iron (ie high nickel alloy cast iron or nickel chrome cast iron), high alloy cast iron material such as anti-wear white cast iron with alloy composition, belongs to non-metallic binder cubic boron nitride insert, its characteristics except high hardness In addition to wear resistance and high-speed cutting, it also has good impact resistance and toughness. It is suitable for mass production and processing of various high-alloy cast iron materials, roughing and finishing.

The following is a brief introduction to the case of Hualing superhard cubic boron nitride tool BN-K1 grade processing high alloy cast iron.
Fourth, Valin super hard cubic boron nitride blade BN-K1 grade car processing high alloy cast iron case
(1) For high-alloy cast iron rolls of HSD75 or higher, the hardness of the rolls is high, and the large-size high-alloy cast iron roll blanks generally have casting defects, which have high requirements on the impact resistance, high temperature resistance and wear resistance of the inserts; At present, the BN-K1 grade of cubic boron nitride insert is commonly used to process such high alloy cast iron rolls. This blade maintains the hardness and wear resistance of the cubic boron nitride tool. It has good impact toughness and is not easy to be collapsed. It can pull rough steel for high alloy cast iron rolls and can withstand large cutting depth and metal removal rate. high.
Take the machining of Nichrome cast iron rolls as an example (pictured)

Roll hardness: HSD80
Processing tool: BN-K1
Cutting parameters: ap=4mm
        Fr=1mm/r
      Vc=55m/min
Cutting method: dry cutting.
The effect of Valin BN-K1 and ceramic blade is as follows: On the basis of the feed of Hualing BN-K1 grade is twice that of ceramic blade, the single-blade life of Valin BN-K1 grade is six of ceramic blade. Double, which increases processing efficiency and reduces processing costs.

(2) Taking the BN-K1 grade intermittently cutting high-chromium alloy cast iron slurry pump impeller as an example: Since the high-alloy cast iron impeller has 5-8 blades, there is intermittent cutting when turning the outer and end faces. The turning parameters of the BN-K1 grade tool are: vc=75m/min, ap=2.5-5mm, f=0.1mm/r. In the process of turning high-alloy cast iron parts, the tool must withstand 5 times to 8 impacts per revolution of the impeller, and one blade must withstand more than 3,000 impacts in one pass. The results show that the BN-K1 grade cubic boron nitride tool has no fracture and fracture during the interrupted cutting process. One tool is equivalent to 7 ceramic tools, which fully demonstrates the impact resistance of the cubic boron nitride tool, which not only reduces the use of the tool. Cost and turning efficiency have also increased by 5 times.
V. Summary
With the rapid development of various difficult materials such as high alloy and high hardness, it is also a challenge for the cutting tool industry. For the tool companies, there is only continuous breakthrough, and the research and development of new types are more wear-resistant and impact-resistant. The tough tool material or tool grade, as well as the combined tool structure suitable for improving the processing efficiency, can realize the localization of high-speed cutting tools as soon as possible, and further promote the development of China's machinery manufacturing industry.

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