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Whole Welding CBN Inserts

Processed Material: Hardened Steel, high strength cast iron, Powder Metallurgy, Gray Cast Iron, Powder Metallurgical
Processing Methods: Finishing, semi-finishing and roughing.
Application: Brake disc, compressor flange, brake drum, gears, valve, bearing, roller, grinding roller, engine cylinder head, cylinder sleeve, cylinder block, etc.

Cubic Boron Nitride (CBN) is a superhard material whose hardness is second only to diamond. It not only has many excellent characteristics of diamond, but also has higher thermal stability and chemical inertness to iron group metals and their alloys.

DNGA series CBN multi-tipped inserts are welding blades. The shape of the inserts is 55 °diamond. CBN material is welded to the cemented carbide substrate through professional flux to improve cutting performance and reduce production costs.


The V type CBN braze inserts (VNGA1604) has a small and exquisite cutting head, high wear resistance, and can withstand larger cutting forces. Vacuum welding is now used to replace the original high-frequency welding, and overall welding is used to replace the original single-sided welding. Advanced processing technology improves the bonding strength between the cutter head and the cutter body. Compared with the previous integrated composite inserts, it avoids the processing problems caused by the delamination of the CBN layer, is durable, reduces the tool change time, and reduces the tool cost. Due to the use of integrated welding technology, both sides of the insert can be processed to increase the cutting edge, the tool utilization is improved.

The W type CBN braze inserts has a small and exquisite cutting head, high wear resistance, and can withstand larger cutting forces. Vacuum welding is now used to replace the original high-frequency welding, and overall welding is used to replace the original single-sided welding. Advanced processing technology improves the bonding strength between the cutter head and the cutter body. Compared with the previous integrated composite inserts, it avoids the processing problems caused by the delamination of the CBN layer, is durable, reduces the tool change time, and reduces the tool cost. Due to the use of integrated welding technology, both sides of the insert can be processed to increase the cutting edge, the tool utilization is improved.

TNGA1604-ZH series CBN braze inserts are indexable CNC inserts with machine clamps. They have 6 cutting edges for easy tool change and reduced tool setting time. Has been successfully applied to brake discs, rollers, bearings, flanges, engine cylinder heads, compressor parts and other workpieces.

When processing hardened steel with PCBN tools, the quenching hardness of the workpiece is required to be higher than 45~55HRC. When processing hard cast iron, as long as the hardness reaches the medium hardness level (45HRC), good processing results will be achieved. For example, the exhaust valve seat on the cylinder head of an automobile engine is made of high chromium alloy cast iron material containing copper and molybdenum, and its hardness is generally about 44HRC

Advantages

1. Wide applicability. Can meet rough, semi-finish and finish processing;
2. High bending strength, suitable for high-speed cutting with large cutting depth;
3. Many cutting edges and high inserts utilization;
4. High fracture toughness. Suitable for continuous, weak intermittent, strong intermittent environmental cutting;
5. Can process countersink or through-hole blades, making clamping more firm;
6. Welding temperature of 800 degrees, can withstand 650 degrees of cutting temperature without falling off;
7. The corresponding clamping shank is very complete, which can directly replace the coated blade without replacing the shank.
8. Can be regrind, but limited times;
9. This structure is recommended for hard steel processing;

Application

whole welding cbn inserts 7

Parameters

whole welding cbn inserts 3

Model: CNGA1204-ZH
Cutting Edge Length(mm): 12.9
Inscribed Circle(mm) : 12.7
Thickness(mm): 4.76
Grade: BTS6000   BTS6000A   BTS2800   BTS7800
Remark: Nose Radius

whole welding cbn inserts 4

Model: TNGA1604-ZH
Cutting Edge Length(mm): 16.5
Inscribed Circle(mm) : 9.525
Thickness(mm): 4.76
Grade: BTS6000   BTS6000A   BTS2800   BTS7800
Remark: Nose Radius

whole welding cbn inserts 1

Model: WNGA0804-ZH
Cutting Edge Length(mm): 8.7
Inscribed Circle(mm) : 12.7
Thickness(mm): 4.76
Grade: BTS6000   BTS6000A   BTS2800   BTS7800
Remark: Nose Radius

whole welding cbn inserts 5

Model: VNGA1604-ZH
Cutting Edge Length(mm): 16.6
Inscribed Circle(mm) : 9.525
Thickness(mm): 4.76
Grade: BTS6000   BTS6000A   BTS2800   BTS7800
Remark: Nose Radius

whole welding cbn inserts 3

Model: DNGA1504-ZH
Cutting Edge Length(mm): 15.5
Inscribed Circle(mm) : 12.7
Thickness(mm): 4.76
Grade: BTS6000   BTS6000A   BTS2800   BTS7800
Remark: Nose Radius

Model: DNGA1506-ZH
Cutting Edge Length(mm): 15.5
Inscribed Circle(mm) : 12.7
Thickness(mm): 6.35
Grade: BTS6000   BTS6000A   BTS2800   BTS7800
Remark: Nose Radius

CBN Grades&Application of PCBN Inserts

CBN grade Average

particle size

CBN

content

Bonding Workpiece material Cutting distance Application
μm % Metal Ceramic Long Short
BT(S)2800 28 95 GCI, CHS × Industrial pumps, valves, brake discs, brake drums, bearings, cylinder liners, rollers, grinding rollers, etc.
BT(S)2800A 20 95 ×
BT(S)2805 14 95 ×
BT(S)2900 7 70 ×
BT(S)6000 2.5 60 FHS × Ball screw, bearing, drive shaft, gear, etc
BT(S)6000-A 2.5 60 ×
BT(S)7800 2.5 80 GCI, ACI × Brake disc, brake drum, gearbox housing, engine cylinder head, cylinder liners, cylinder block, etc.
BT(S)9000 3.5 80 × GCI ×
BT(S)8000 10 85 × DI, ACI,

FHS

× Engine cylinder head, cylinder liner, cylinder block, crankshaft, lead screw, bearing, drive shaft, gear, etc.
BT(S)8000A 2.5 80 × ×
BT(S)8800 1.5 75 × ×
BT(S)8600 1 80 FHS × Ball screw, bearing, drive shaft, gear, etc.
 Remark: 1. The cutting distance of each workpiece more than 240m are thought to be long distance cutting, otherwise it is short distance cutting.
                2. Workpiece material: Cast hard steel(CHS), Forging hard steel(FHS), Grey cast iron(GCI), Alloy cast iron(ACI), Ductile iron(DI)
                3. “√”=Yes,  “×”=No.

 

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