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Advantages of cBN tools in hardened steel machining

Advantages of cBN tools in hardened steel machining

Advantages of cBN tools in hardened steel machining

Proper cutting work

requires a tool that is three times harder than the work material!

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Characteristics of cBN end mill

Characteristics of cBN end mill

Concept of cBN end mill

Innovation from electrical discharge machining to direct milling

  • Reduced delivery time Example: Previously, 5 days for mold designing + 5 days for electrode processing + 5 days for electrical discharging/finishing, or 15 days in total. Presently, 5 days for mold designing + 1 day for direct milling, or 6 days in total.
  • Reduced cost (75% reduction in power consumption, and no need for electrode fabrication) → Resource savings
  • No drain from electrical discharge machining (0Eco-friendly)

Cuts two times faster and lasts five times longer than carbide-coated tools.

  • Reduced machining time
  • Fewer changes of tools during long period of cutting
  • Less time for polishing process

Direct milling vs. electrical discharge machining

Workpiece Bevel gear cavity (60×60×50)
Work material DC53 (HRC60)
Processing machine Yasuda Precision Tools YBM640V
Cutting fluid Oil mist (cBN for dry machining)
Tools used Five carbide end mills, eight R1s, one cBN end mill
Machining description Machining test by direct milling with carbide tools and cBN tool. (Time and surface roughness compared with conventional electrical discharge machining)
Cutting conditions
Machining process Tool used Rotational frequency (min−1) Feed(mm/min) Machining time(min)
Prepared hole machining Carbide R5 ball end mill 600 240 7.4
Roughing Carbide φ10 end mill 4,000 2,500 6.2
Semi-roughing Carbide R3 ball end mill 5,000 1,200 19.0
Semi-finishing Carbide R1.0 ball end mill 8,500 2,000 36.1
Semi-finishing Carbide R1.0 ball end mill 15,000 2,400 28.5
Final finishing cBN R1.0 ball end mill 20,000 2,000 50.3
Prepared hole machining Carbide R5 ball end mill 600 240 7.4
Roughing Carbide φ10 end mill 4,000 2,500 6.2
Semi-roughing Carbide R3 ball end mill 5,000 1,200 19.0
Semi-finishing Carbide R1.5 ball end mill 8,500 2,000 36.1
Semi-finishing Carbide R1.0 ball end mill 15,000 2,400 28.5
Final finishing cBN R1.0 ball end mill 20,000 2,000 50.3

Conclusion:
Approx. 10 h with conventional method (electrical discharge machining + polishing) vs. approx. 2.5 h with direct milling method
This translates to a 75% reduction in time.

Features of our CBN tool: Electrolytic abrasive grain polishing

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Unprocessed product (Grinding stone traces are seen, with the likelihood of causing surface accuracy deterioration and chipping.) Processed product (The smooth cutting edge provides high accuracy and long life.)

Processing of cBN cutting edge

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