Super Hard Grade Design

Superhard Materials
Hardness Comparison
7000
6500
6000
5500
Knoop Hardness

5000
4500
(kg/mm2)

4000
3500
3000
2500
2000
1500
1000
500
0
Diamond CBN SiC Al2O3 WC
 Superhard Materials
Target Workpiece Materials

PCD - Polycrystalline Diamond

CVDD - Chemical Vapor Deposition of Diamond
Non-Ferrous (Metallic and Non-Metallic)

PCBN - Polycrystalline Cubic Boron Nitride

Hardened Steels and Irons
Cast Irons
Heat Resistant Alloys
 Superhard Materials
Economic Justification

Highest Tooling Unit Prices

$20 - $5000

Lowest Cost/Part
High Metal Removal Rates
Long Tool Life
Surface Finish Attainment
Size Tolerance
 Superhard Materials
Diamond Machining Conditions
Operating Conditions
Workpiece Material Speed (m./min.) Feed (mm./rev.)
Aluminum Alloys
4% - 8% Si 900 - 3,000 0.10 - 0.60
9% - 12% Si 600 - 2,400 0.10 - 0.50
>12% Si 300 - 700 0.10 - 0.40

Copper Alloys 600 - 1,000 0.05 - 0.20

Plastics / Composites 300 - 1,000 0.10 - 0.30

Sintered WC 20 - 40 0.15 - 0.25
Manufactured Wood 1,000 - 3,000 0.10 - 0.20
Superhard Materials
PCBN Products
 Superhard Materials
PCBN Target Workpiece Materials
Cast Iron Sintered Iron
Hard: Alloy, Chilled, Nodular
Powdered Metal
Ni-Hard
Soft: Gray Cast Iron

Hardened Steels (48 - 65 HRc) Superalloys

Tool, die and Bearing Steels Hastelloy
Stellite/Waspalloy
Case Hardened/Heat Treated
Inconnel 718, 901 600
Chromealloy
Rene 77, 95
 Superhard Materials
PCBN Microstructure

High Content, Large Grain Size
Comp.: 82 Vol % CBN/Ceramic
Ave. Particle Size: 15 m
Density (g/cc): 3.4
Knoop Hardness: 3200
High Content Small Grain Size Low Content
Comp.: 90 Vol % CBN/Metal Comp.: 65 Vol % CBN/TiN
Average Particle Size: 2 m Ave. Particle Size: 2 m
Density (g/cc): 4.0 Density (g/cc): 4.1
Knoop Hardness: 2800 Knoop Hardness: 2500
 Superhard Materials
PCBN Grades

Low Content
PCBN - 50%
Cutting
Speed Low Content
PCBN - 60%
High Content
2 m High Content
15 m

Continuous Light Middle Severe

Cutting Interrupted Cutting
 Superhard Materials
PCBN Edge Preparation
 Time Cost Comparisons
Grinding Process Hard Turn Process
Operation Time (mins.) Operation Time
Setup OD & Face 15 Setup Lathe (mins.) 25
Grind OD & Face 5 3 Tools
Setup ID 30 Hard Turn
Grind ID 10 Turn & Face 1.5
Bore I.D. 0.7
Setup Taper 40
Turn Angle 1.1
Grind Taper 4
Setup Time 85 Setup Time 25
Run Time 19 Run time 3.3
Setup reduction: 71%
Cycle time reduction: 83%
 Superhard Materials
PCBN Tool Failure Wear Mechanisms
Cast Iron Turning Cast Iron Grooving Hard Steel Machining Ferritic Cast Iron Turning

Abrasive Wear Chemical Wear

Interrupted Hard Interrupted Hard Interrupted Hard
Cast Iron Milling Steel Turning/Wet Steel Turning Steel Turning

Thermal Fatigue Mechanical Impact (Chipping)

 Superhard Materials
PCBN Tool Wear Mechanisms - Crater Wear
Typical PCBN Tool Failure Modes Illustrating Crater Breaking Through
Possible Causes
* Cutting speed too high
* Work material too soft
* Edge not strong enough to
withstand crater breaking through.
* Improper Grade Selection
Solutions
* Change speed to recommended ranges
* Decrease speed/Increase feed the same %
if surface finish specification allows.
* Minimum 45HRc. 60 HRc desirable
* Reduce tool pressure
* Low Content PCBN for hard steel
High Content for cast iron, PM
 Superhard Materials
PCBN Tool Wear Mechanisms - Chipping

Typical PCBN Tool Failure Modes Illustrating Chipping/Fracturing

Possible Causes
* Insufficient Edge Preparation
Solutions
* Increase chamfer angle(hard steel finishing)
Increase chamfer width(iron based materials/roughing applications).
- Increase land angle to 30-35 degrees for severe interruptions.
- Add 0.02 mm. hone on bottom of chamfer to allow for
proper initial cutting edge wear.

* Ensure tool holding mechanisms * Use toolholder with increased support.

provides proper insert seating and Use larger clamp size or shim on insert to increase
support. clamping force.
Machining Hardened Steels (>45 HRc)
Failure mechanism in PCBN tools:
Crater wear
abrasive wear
Crater wear from:
Chemical wear (B & N are soluble in steel)
Oxidation of BN.
Transformation (from hard cubic to softer
hexagonal phase)
Solution: thermal barrier coatings (TiAlN,
Al2O3)
 Coated PCBN Tools

CVD Al2O3 PVD TiAlN

coated tool
Performance Advantage* of TiAlN-Coated
PCBN Tools at Indicated Maximum Wear
Maximum Flank Wear
PCBN Type 0.25 mm 0.38 mm

PCBN + TiC 1.5x 1.3x

PCBN + TiN 2.7x 2.2x

PCBN + TiCN 1.7x 3.0x

PCBN + TiCN 1.2x 1.1x

PCBN + TiC 3.4x 3.7x

* D3 Tool Steel @ 120 m/min, 0.1 mm/rev, 0.5 mm
DOC, dry, SNMA 120408T insert style.