In the highly competitive world of modern machining, PCD (Polycrystalline Diamond) and PCBN (Polycrystalline Cubic Boron Nitride) insert blades have emerged as the vanguard of cutting tool technology, revolutionizing the way we approach machining processes.

PCD Insert Blades

PCD is a composite material consisting of sintered diamond particles with a metallic binder. Diamond, being the hardest material known, endows PCD insert blades with exceptional hardness and wear resistance. These blades are ideal for machining non-ferrous metals and non-metallic materials.

 

• Processing of Non-Ferrous Metals: PCD insert blades are highly effective in processing a wide range of non-ferrous metals such as high or low silicon content aluminum alloys (used in pistons, engine blocks, wheels, carburetors, connecting rods, gear boxes, and brake cylinders), bronze, and copper alloys (found in copper manifolds, engine bearings, bushings, and connecting rod eyes).
• Processing of Non-Metallic Materials: They are also excellent for machining highly abrasive non-metallic materials like ceramics, some fired ceramics (such as zirconia and aluminum oxide like spark plugs and insulators), glass, plastics with glass fibers, and carbon fibers. The high precision and excellent surface finish achieved with PCD insert blades are remarkable. They can provide a machined surface roughness that is comparable to the best in the industry, significantly enhancing the quality of the final product.

PCBN Insert Blades PCBN, on the other hand, is characterized by high thermal stability, high hardness, high wear resistance, and inertness to iron family elements. This makes it predominantly used for the machining of high hardness and hard-processed ferrous materials.

 

• Machining of Hardened Steels: PCBN insert blades are highly suitable for machining hardened steels, which are notoriously difficult to cut with traditional cutting tools. They can maintain their cutting performance even at high temperatures, ensuring efficient and accurate machining1.
• Processing of Cast Irons: Gray cast irons and ductile irons are also within the scope of PCBN insert blades' application. The high hardness and wear resistance of PCBN enable it to handle the unique characteristics of cast irons, providing stable and reliable machining results.
• High-Speed and High-Efficiency Machining: PCBN insert blades are well-suited for high-speed and high-efficiency machining processes. Their excellent thermal conductivity allows for rapid heat dissipation, reducing the heat generated during cutting and minimizing the negative impact on the tool's life and the machining accuracy

Key Industry Terms and Features

 

• Wear Resistance: Both PCD and PCBN insert blades exhibit extremely high wear resistance, which is a crucial factor in reducing tool replacement frequency and increasing machining efficiency. This is especially important in high-volume production scenarios where downtime for tool replacement can significantly impact production costs and schedules.
• Hardness: With hardness levels far exceeding those of traditional cutting tools, PCD and PCBN insert blades can easily cut through hard materials, enabling the machining of complex parts and components that were previously difficult or impossible to process.
• Thermal Stability: The high thermal stability of PCBN insert blades allows them to maintain their performance at high temperatures, while PCD insert blades also have good thermal conductivity, ensuring that the heat generated during cutting is quickly dissipated, thereby reducing the risk of thermal damage to the tool and the workpiece.
• Chip Formation and Control: In machining processes, chip formation and control are essential for ensuring smooth operation and high-quality machining. PCD and PCBN insert blades are designed to optimize chip formation and control, minimizing the occurrence of chip jamming and improving the machining process's stability and safety.

Focusing on revolutionary technological innovation on CBN micro-nano materials, composites and cutting tool application, and advanced controlling and manufacturing process, We are able to develop and manufacture the most consistent high-quality PCBN solid inserts with high impact resistance, more economical double-layer inserts, super finishing single-layer inserts and inserts with cutting-edge coating techniques. It fully meets the requirements of wear resistance, impact resistance, thermal stability and chemical stability of metal machining.

Our PCBN inserts are widely used in processing pearlitic cast iron, high chromium and nickel alloy cast iron, hardened steel, powder metal, hard alloy and super alloy. In the mechanical machining application of the traditional system, not only it has greatly reduced the comprehensive production cost, but also significantly improved the production capacity and efficiency during the whole production operation, and the equipment investment is greatly decreased at the same time.

Advantages of Innovative PCBN Insert:

Excellent cost performance

The service life of PCBN insert can be more than 10 times that of carbide insert and reduce the cost of comprehensive cutting tool by 30%-50%. The interval time between the replacements of PCBN insert is long and the insert replacement frequency is less, which can significantly reduce the cost on inserts.

Excellent surface quality

Surface finish and dimensional precision of machining workpiece of PCBN insert can reach the grinding level, and make turning instead of grinding to reduce equipment investment.

High machining efficiency

The machining efficiency of PCBN insert is 5-10 times that of the carbide insert, which greatly improves the equipment capacity and reduces the fixed investment of equipment.

Strong universality

PCBN insert can be used for both dry cutting and wet cutting and one grade normally is suitable for machining a variety of materials.

 

 

PCBN material characteristics

Polycrystalline cubic boron nitride (PCBN) is made by sintering CBN powder and bond. Because of its low affinity with ferrous metals, it is mainly used for cutting ferrous metals. According to its organization, it can be classified as follows:

▪KB55, KB10 andKB95T are directly sintered from CBN particles with high CBN content and good wear resistance. They are suitable for processing high hardness materials such as cast iron, heat-resistant alloy and cemented carbide.

▪ KB30, KB21, KB61 and KB50 are composed of CBN particles and ceramic binder, which increases the binding force between CBN particles and can effectively inhibit the collapse problem of strong intermittent cutting. They can be used to process quenched steel and other materials, giving play to their excellent wear resistance and strong toughness.

 

PCD&PCBN insert-PRODUCTS-Zhuzhou Wisdom Mining Technology Co., LTD_tungsten alloy_carbide insert (hxy-carbide.com)

In conclusion, PCD and PCBN insert blades are the go-to choices for demanding machining applications that require high precision, high efficiency, and excellent wear resistance. Their unique properties and performance advantages make them indispensable in various industries such as automotive, aerospace, electronics, and mold manufacturing. As the machining industry continues to evolve, the importance of PCD and PCBN insert blades will only continue to grow, driving innovation and progress in the field of precision machining.

ZHUZHOU WISDOM MINING TECHNOLOGY COMPANY LTD.

Email:zztungsten@hxy-carbide.comv

TEL:+86073128107629

Moblie&Wechat:15367337266

Website:https://www.hxy-carbide.com/