1.2 Application in Milling
The gray cast iron is milled with a PCBN tool with a cutting speed of 1,000 to 000 m/min; the aluminum alloy is milled with a PCD tool at speeds of 3,000 to 4,000 m/min.
The PCD face milling cutter for processing aluminum alloy cylinder heads has a milling speed of 4,021 m/min and a feed rate of 5,670 mm/min. The efficiency is twice that of the introduction of the production line in China in the early 1990s.
The CBN face milling cutter for finishing gray cast iron cylinders has a milling speed of 2,000 m/min, which is 10 times that of hard alloy face milling cutters.
The PCD spiral inner drain face milling cutter for milling glass has various diameters of 10mm, 12mm, 16mm and 20mm, and is widely used in glass deep processing.
On the X53K vertical milling machine, the milling of Cr12MoV (HRc59~61) and 45 steel (HRc50～53) materials with PCBN end mill provides useful reference data for the practical application of such tools. PCD tools have a high wear resistance when milling graphite. Many experts have used PCD milling cutters on the Mikron Nidau high-speed cutting and milling machine in Switzerland. One clamping tool can process 20 toothbrush electrodes and still achieve the requirement of shape tolerance less than 0.01mm. PCBN tool hard milling shower nozzle handle steel mold, high precision, only need to be slightly polished after milling.
1.3 Application in boring processing
At present, there are many engine manufacturers in China that use PCBN tools to finish the V-cylinders of cylinder cylinders. For example, the engine plants of Shanghai Volkswagen and FAW Group use PCBN inserts and can automatically compensate (V=500m/min, ƒ= 0.2 mm / r, ap = 0.1 mm). Long tool life, high machining accuracy, dimensional stability and high production efficiency.
FAW uses PCD tools to precision silicon aluminum alloy piston pin holes (V=160m/min, ƒ=0.08~0.10mm/r, ap=0.05mm.), with a durability of 42,500 pieces, which is a carbide tool. 90 times; the surface roughness Ra is reduced from the original 1.12 to 0.15; each class can reduce the auxiliary time of the adjustment tool for 30min, and the cost is about 85% lower than that of the cemented carbide tool.
PCBN tools are 50 times more wear resistant than cemented carbide tools, several times higher than coated carbide tools and 25 times higher than ceramic tools, making them the only efficient tool for machining non-metallic materials. The highest cutting speed is 7,000m/min; the efficiency is significantly improved.
CVD tool for boring tungsten carbide (25% Co) cylinder (inner diameter 20mm, length 40mm), adding coolant, cutting speed 0.5m / s, cutting depth 0.12mm, 8 clamping tools can be processed Components.
Casting silicon aluminum alloy SAE327 with PCD cutter (Si7～8.6%, Cu1～2%, Mg0.25%～0.6%, Mn0.5%～0.8%; tensile strength>230MPa, hardness 110～130HB, elongation> 1%) The refrigeration compressor connecting rod is a high-speed dry boring hole with a cutting speed of 140-180 m/min, Ra 0.02-0.32 μm, and an accuracy of 5-7.
1.4 Application in broaching
The composite involute toothed inner hole super-hard material broach is used to machine the workpiece hole. The advantages are as follows: (1) Since the coaxiality between the various shapes of the inner hole of the workpiece can be reliably ensured, the small diameter can be uniformly used in the subsequent processing steps. The circular surface is used as the positioning reference, which greatly facilitates the production of the post-positioning positioning mandrel and the inspection mandrel, and reliably ensures the positional accuracy of all the machined surfaces; (2) due to the reasonable tooth-hopping arrangement and the spline-blade opening side The cutter tooth structure ensures the manufacturing quality of the broach and is easy to manufacture, and the cost is almost the same as that of the ordinary composite involute broach.
