Four Structural Forms of PCBN Cutting Tools

Ⅰ. Introduction of PCBN cutting tools

The PCBN cutting tool is a complex whole formed by direct sintering of a PCBN layer of about 0.5mm on a cemented carbide substrate. This material not only has the high hardness, high thermal stability and high chemical stability of PCBN, but also has the advantages of good cemented carbide strength and good weldability, so that PCBN cutting tools can not only cut workpieces of various hardness, but also are easy to produce.

Ⅱ. The structure of PCBN cutting tools

1. Whole sintered PCBN cutting tools

1）Physical geometry characteristics:

•  High toughness;
  

•  High bending strength;
  

•  Can withstand a high temperature of 1400 degrees;
  

•  With many tool tips, and each tip can cut.
  

2）Application scope and advantages:

• It can meet rough, semi-finish and finishing processing;
  

• Suitable for continuous, weakly interrupted, and strongly interrupted cutting environments;
  

•  Suitable for high-speed cutting with large depth of cut;
  

•  Counterbore or through-hole can be processed, and the clamping is firmer;
  

•  This structure is the first choice for hard steel processing;
  

•  Unlimited regrind with high cutting tools utilization.
  

2. Overall welding PCBN cutting tools

1) Physical geometry characteristics:

• The tip is made of integral sintered material, which has good chipping resistance.
  

•  The welding temperature is over 900 degrees, and the tip can withstand the cutting temperature of 750 degrees without falling off;

•  The welding tip can withstand lower cutting resistance than the integral sintered and integral composite cutting tools.
  

• Only sharp-angled tip is available. For example, C1204 has 4 tool tips.
  

2) Application scope and advantages:

• It can meet rough, semi-finish and finishing processing;
  

• High welding strength, can withstand higher cutting temperature and cutting force;
  

• Suitable for cutting depth <3mm processing conditions, can meet the strong interruption, weak interruption and continuous processing environment;
  

• Corresponding to the entire clamping tool bar, it can directly replace the coated cutting tools without changing the tool bar;
  

• This structure is recommended for hard steel processing;
  

• It can be reground, but the number of times is limited.
  

3. Composite welding PCBN cutting tools

1) Physical geometry characteristics:

• The tool tip is made of composite material, which is brittle and has poor chipping resistance;
  

• The welding temperature is 800 degrees, which can withstand the cutting temperature of 650 degrees without falling off;
  

•  The number of tool tips is twice as small as the overall welding. Individual small cutting tools have only one tip.
  

2) Application scope and advantages:

• Suitable for semi-finishing and finishing needs;

• Suitable for cutting depth <0.5mm, weakly interrupted and continuous finishing environment;

• Desoldering probability increases in an environment with high cutting temperature;

•  Cannot regrind.

4. Overall composite PCBN cutting tools

1) Physical geometry characteristics:

• The tool tip is made of composite material, which is brittle and easy to chip;
  

• Direct compound under high temperature and high pressure, the high temperature resistance is the same as the integral sintered cutting tools;
  

• The number of tool tips is the same as the overall sintered cutting tools;
  

• The flexural strength and fracture toughness are worse than that of the integral sintered cutting tools.
  

2) Application scope and advantages:

• High bonding strength between composite layer and substrate;

• Suitable for 0-5mm cutting depth, continuous and lightly interrupted cutting;

• It can meet the needs of rough machining, semi-finishing and finishing;

• Unlimited regrind.