The charm of Chinese knives is its low cost, which is very competitive with the cost of 20%-30% lower than Japanese knives. The key to the tool industry is to be competitive in the market. The Chinese tool market is not cheap, because it only sees the surface, is cheap, and can be profitable. It is necessary to carefully analyze the Chinese tool market. In addition to productivity, product performance and other factors, the so-called "profitable tools" should also have a significant factor in reducing tool costs. Since the engine factory of Dongfeng Motor Corporation used PCBN tools in 1988, its effect has remained stable, which has solved the problem of localization of tools imported equipment. With the rapid development of China's automobile manufacturing industry, the domestic tool industry is also very active and flourishing. Tool companies at home and abroad have taken a fancy to China's big market, but these foreign tool companies have just entered China when they entered China. The development of the market is not enough. Some of them only entrusted Chinese agents to sell some of the knives, and the after-sales service has not been able to keep up with it. In addition, Vasaki is a company that is a super-hard tool in the Guangfo area. It also set up a production factory in Shunde, specializing in the processing and grinding of super-hard tools such as diamond tools and CBN tools. The quality of the products is especially good for imported tools, and its business volume is also very large, helping many customers solve super-hard tools. Grinding work. Application of Cubic Boron Nitride (CBN) in Machining Using PCBN Blade Finishing Hardened Steel Processing Hard Cast Iron and Gray Cast Iron High Speed ​​Boring Casting Hole Reaming Hardened Steel or Hard Casting Holes for Cutting of Difficult Machining Materials The processing uses PCBN tool to finish hardened steel, and the hardness of the workpiece is higher than 45HRC, which has the best effect. The cutting speed is generally 80-120 m/min. The higher the hardness of the workpiece, the lower the cutting speed. For example, the workpiece with a hardness of 70HRC should be 60-80m/min. The cutting depth of the finished car is 0.1-0.3mm, the feed rate is 0.05-0.025mm/r, the surface roughness of the workpiece after finishing the car is Ra0.3-0.6μm, and the dimensional accuracy can reach 0.013mm. If the standard CNC lathe machining with good rigidity can be used, the rigidity of the PCBN tool is good and the edge is sharp. The surface roughness of the workpiece after finishing the car can reach Ra0.3μm, the dimensional accuracy can reach 0.01mm, and it can be processed by CNC grinding machine. Level. If the machine tool is rigid and the cutting speed is low, the PCBN compound blade can be used to finish the surface. The finishing allowance of the finishing car is generally about 0.3mm, which can improve the dimensional accuracy and reduce the thermal deformation of the workpiece before quenching as much as possible to ensure uniform cutting allowance and prolong the service life of the PCBN tool. The finishing car generally does not use cutting fluid, because at higher cutting speeds, a large amount of cutting heat is carried away by the chips, and rarely stays on the surface of the workpiece to affect the quality and precision of the machined surface. The finishing blade should use a 80° diamond blade with high strength and toughness. The radius of the tool tip is between 0.8 and 1.2 mm. To protect the cutting edge of the tool, a fine stone chamfer is required before use. Finished car hardened workpiece is a new process. It needs to be tested before implementation. It can be used for finishing or roughing test on the same machine tool with the same material, hardness and size. The key is to test the tool and cut. The choice of parameters and the process system are sufficiently rigid. The process has been adopted in China at present. For example, FAW Group uses PCBN tools to process carburizing and quenching (58-63HRC) 20CrMnTi gearbox shift fork groove. The process parameters are Vc=150m/min, f=0.1mm/r, ap = 0.2 ~ 0.3mm, the realization of the car to wear. Machining hard cast iron When turning hardened steel with PCBN tool, the hardening hardness of the workpiece is required to be higher than 45-55HRC. When the hard cast iron is processed, as long as the hardness reaches the medium hardness level (45HRC), good processing results will be obtained. 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. Its hardness is generally about 44HRC, and the upper hole of the valve seat adopts two processes: 锪 (hinge) and car. Most of them are processed on a dedicated automatic line, along with the gun hinge hole. The cutting amount used is: Vc=71.6m/min, Vf=26.5mm/min, ap=1.0mm, using BC broaching oil, after processing with PCBN tool, it is processed with various carbide blades used in the past. In comparison, the average durability of the tool is 1200 pieces, the surface roughness of the machined surface is Ra0.4μm, and the valve seat surface slip is ≤0.05mm. When high-speed milling gray cast iron is used for high-speed milling of gray cast iron, it is of course possible to use K-type cemented carbide for rough machining, and for the processing of silicon-silicon ceramic inserts. For example, if you use a symmetrical two-piece PCBN insert on an end mill with 8 inserts and increase the cutting speed by 4 times, the result is the same metal removal rate and a 3/4 reduction in cutting force. Tool life and processing quality exceed the former. For pearlite cast iron and chilled cast iron, PCBN tools should also be used for high-speed machining. Compared with other tool materials, it can improve cutting speed, extend tool life and reduce surface roughness. Compared with the single-piece boring tool, the paired insert PCBN boring tool on the high-speed mast has a good balance, which increases the rigidity of the mast. At a given feed rate, the PCBN double-blade boring can be used. A high metal removal rate and surface quality are obtained. At present, there are many engine manufacturers in China, and PCBN tools have been used for finishing the cylinder bore (or cylinder liner) of the cylinder block. As the engine manufacturers of Shanghai Volkswagen and FAW Group, the cylinder bores are made of PCBN inserts and can be automatically compensated (υc=500m/min, f=0.2mm/r, ap=0.1mm). Therefore, the processed cylinder bore has high precision and dimensional stability, and has high production efficiency and long tool life. For small hole boring, ceramic or coated blades can be used, but the blade should have a negative rake angle, which will increase the resistance to cutting and chip removal, and easily cause the slender mast to vibrate. If the PCBN tool is used for high-speed boring, the surface quality of the hole is good and the production efficiency is high. CBN electroplated reamer should be used for the hole machining of such workpieces. This kind of reamer is made of 45# steel or 9CrSi steel with a hardness of 42HRC. It has front and rear guiding and cutting parts. The base manufacturing precision is high and the design should be reasonable. If the diameter of the front guiding portion of the reamer is smaller than the diameter of the cutting edge portion by 0.04 mm, the length of the cutting zone is larger than the depth of the workpiece hole, and the length of the rear guiding is greater than the length of the cutting zone, and the diameter should be smaller than the diameter of the cutting edge of 0.02 mm. In order to flush the chips with the cutting fluid and to cool the lubricated surface in the reaming, the reamer base has two deep spiral grooves. For example, if a factory processes hardened steel workpiece holes f12.06±0.05mm, the hardness is 45HRC, the bottom hole size is f12±0.01mm, the cylindricity of the hole is required to be 0.005mm, and the surface roughness is Ra0.2μm. After processing with a set of five electroplated CBN reamers, good economic results are achieved. Some engine manufacturers use diamond or CBN electroplating reamer to knead the main bearing hole of the cylinder block instead of the original honing process, which improves the processing efficiency several times and the quality is stable. Use PCBN tool with positive rake angle, select appropriate cutting parameters, namely Vc=100m/min, f=0.05～0.2mm, ap=0.1～0.2mm, use extreme pressure type emulsion or oil coolant, can process Materials such as stainless steel (45HRC), high-temperature alloy steel, high-manganese steel, high-strength steel and high-nickel alloy steel can obtain high processing efficiency and surface quality.
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