PCBN Tools for Hard Turning
1. Halnn CBN Materials for Hard Turning
CBN Grade | Blinder | CBN Content | Granularity （μm） | Hardness |
BN-S20 | TIN | 76 | 4~6 | 2900-3100 |
BN-S200 | TIN | 60 | 2~4 | 2800-3000 |
BN-H11 | TIN | 70 | 2~4 | 2800-3000 |
BN-H20 | TIC | 80 | 2~4 | 3100-3300 |
BN-H05 | TIN | 45 | ≤1 | 2700-2800 |
BN-H10 | TIN | 50 | ≤1 | 2700-2800 |
BN-H21 | AL,TINC | 60 | 1~2 | 2600-2800 |
BN-H05 C25 | TIN | 45 | ≤1 | 2700-2800 |
BN-H10 C25 | TIN | 50 | ≤1 | 2700-2800 |
BN-H21 C25 | AL,TINC | 60 | 1~2 | 2600-2800 |
CBNContent | Characteristics | Insert Grade | Depth of Cut (mm) | Recommend Cutting condition | Suited Materials | Typical Application |
Low Content CBN | Toughnes (Roughing)
Hardness (Finishing) | BN-S20 | 1-10mm | Interrupt-Continuous | Hardened Steel, Heat and abrasive resistant steel, High manganese steel | HSS Rolls, Ball Screw, Wind Power Bearings |
BN-H20 | ≤1mm | Semi-Interrupt | Hardened steel, other materials of difficult to machine | Hardened Steel Gears, Mold,ect | ||
BN-S200 | ≤1mm | Continuous | Hardened Steel, Superalloy | Wind Power Bearings | ||
BN-H11 | ≤1mm | Continuous | Hardened Steel | Bearings, Gears, Gear Shaft, Hardened Mold | ||
Hardness Toughness | BN-H05 | ≤0.2mm | Continuous | Hardened Steel | Gears,Gear Shaft, Bearings | |
BN-H10 | ≤0.5mm | Continuous-Semi-interrupt | Hardened Steel, high strength cast iron | Bearings, Gears, Gear Shaft, High hardness component | ||
BN-H21 | ≤0.5mm | Semi-interrupt—Heavy Interrupt | Hardened Steel | Bearings, Gears, Gear Shaft,Mold,ect. | ||
Hardness Toughness | BN-H05 C25 | ≤0.2mm | Continuous | Hardened Steel | Gears,Gear Shaft, Bearings | |
BN-H10 C25 | ≤0.5mm | Continuous~Semi-Interrupt | Hardened Steel, high strength cast iron | Bearings, Gears, Gear Shaft, High hardness component | ||
BN-H21 C25 | ≤0.5mm | Semi-Interrupt~Heavy Interrupt | Hardened Steel | Bearings, Gears, Gear Shaft,Mold,ect. |
2. Typical Application Case
| BN-H10 PCBN Insert Hard turning automotive Transmission gear shaft | ||
 | Component | Transmission gear shaft |
| Materials & Hardness | 20CrMo,62-65HRC | |
| Selected Insert | BN-H10 VNGA160408 | |
| Cutting Parameters | Vc=132m/min,ap=0.1mm,fr=0.15mm/r | |
| Roughness | Ra1.6 | |
| Coolant Method | Wet Cutting | |
| CBN Materials | Selected Insert | Average tool life (pieces/tip) |
| Kyocera PCBN | KBN25M VNGA160408 S01225 | 100 |
| Halnn PCBN | BN-H10 VNGA160408T01535 | 145 |
| With Halnn BN-H10, tool life improved 45%! | ||
BN-H05 PCBN Insert Continuous turning Gear Inner Bore | ||
| Machining Condition: | Continuous Turning |
Materials & Hardness | 20CrMnTi Gears,HRC58-62 | |
Selected Insert | BN-H05 CNGA120408 | |
Cutting Condition | ap=0.1mm,Fr=0.1mm/r,Vc=180m/min,Dry Cutting | |
Insert Materials | Roughness | Tool Life |
Halnn BN-H05 | ≤Ra0.8 | 800 pieces |
Other Brand PCBN | Ra1.0 | 550 pieces |
With BN-H05 PCBN Insert, the Tool life will improve 45%! | ||
BN-H10 PCBN Insert Light Interrupt turning Gear inner bore | |||
| Machining Condition | Semi-Interrupt turning inner bore | |
Materials | 20CrMnTi Gears, HRC58~62 | ||
Selected Insert | BN-H10 CCGW09T304 | ||
Cutting Condition | ap=0.25mm,Fr=0.08mm/r,Vc=135m/min,dry cutting | ||
Cutting Tools Materials | Cutting Speed | Tool Life | Efficiency |
Halnn BN-H10 | 135m/min | 1000 pieces | Improved 22% |
Other PCBN Insert | 110m/min | 600 pieces | ---- |
With BN-H10 PCBN hard turning the gears with keyway, the efficiency will improve about 22% ! | |||
BN-H21 PCBN Insert heavy Interrupt turning Gear EndSurface | |||
| Machining Condition | Heavy Interrupt turning Endsurface | |
Materials | 20CrMnTi Gears, HRC58~62 | ||
Selected Insert | BN-H21 WNGA080404 | ||
Cutting Condition | ap=0.15mm,Fr=0.1mm/r,Vc=117m/min,dry cutting | ||
Cutting Tools Materials | Tool Life | Failure Mode | |
Halnn BN-H21 | 600 pieces | Normal Wear | |
Other PCBN Insert | 100 pieces | Damaged | |
With BN-H21 PCBN Insert, the tool life improved about 5 times, it will not chip when meet heavy interrupt condition. | |||
| Halnn Coating PCBN Insert machining Gears | ||
 | Component Materials | 20CrMnTi, HRC58~62 |
| Selected Insert | BN-H05 CNGA120408 | |
| Cutting Condition | Ap=0.1mm, Fr=0.1mm/r,Vc=180m/min | |
Insert Materials | Roughness | Tool Life (pieces/insert) |
Other PCBN | Ra1.0 | 550 |
Halnn BN-H05 | Ra≤0.8 | 800 |
Halnn BN-H05 C25 | Ra≤0.8 | 1200 |
| With Coating PCBN Bn-H05 C25, the tool life will be improved about 50% than Bn-H05 without coating. | ||
BN-S20 Solid CBN Insert hard turning Ball Screw | ||
| Materials & Hardness | Rolling Screw Gcr15, HRC60-62 |
Selected Insert | BN-S20 CNGN120708 | |
Cutting Parameters | ap=4.5mm,Fr=0.10mm/r,Vc=95m/min, | |
| Insert Materials | Cutting Depth | Failure Mode |
| Halnn BN-S20 | 4.5mm | Normal Wear |
| Ceramic Insert | 0.5mm | Damaged |
BN-S20 can achieve the cutting depth 4.5mm, and also normal wear. | ||
BN-H10 PCBN Insert hard turning Ball Screw Raceway | ||
| Materials & Hardness | Rolling Screw Thread Gcr15, HRC60-62 |
Selected Insert | BN-H10 Customized PCBN Inserts | |
Cutting Parameters | Fr=0.10mm/r,Vc=150m/min, | |
| Insert Materials | Roughness | Failure Mode |
| Halnn BN-H10 | ≤Ra0.8 | Normal Wear |
| Other PCBN Inserts | Ra1.2~1.6 | Damaged |
BN-H10 make the roughness with Ra0.8,Normal Wear | ||
| BN-H10 PCBN insert Hard Turning Wind Power Bearings | |||
 | Materials & Hardness | Wind Power Bearings 42CrMo,Hrc58~62 | |
| Selected Insert | BN-H10 RNGN090300 | ||
| Cutting parameters | ap=1mm(Roughing),ap=0.15mm(Finishing),Fr=0.45mm/r, Vc=145m/min, dry cutting | ||
| Insert Materials | Cutting Speed | Tool Life | Efficiency |
| Halnn BN-H10 | 145m/min | 3pcs/blade | Improve 20% |
| Other PCBN Inserts | 120m/min | 2pcs/blade | Improve 20% |
| With BN-H10. the efficiency will improve about 20%, and the tool life improve about 50%. | |||