Application Background
Hardened steel is steel that has undergone quenching to form a martensitic structure with a hardness exceeding HRC 50. Due to its high hardness, high strength, excellent wear resistance, good thermal stability, and low plasticity, it is widely used in transportation, energy, chemical, engineering machinery, and other fields. Turning hardened steel parts typically faces the following challenges:
●Rapid tool wear
●High cutting temperature
●Difficult dimensional accuracy control
●Poor machining quality
●Chip breaking and entanglement issues in continuous finishing operations
Solution Analysis
◎ In this case, the objective conditions are: the workpiece material is HRC 58–62 hardened steel with high hardness, the machining condition is continuous finish turning with dry cutting, and the surface roughness requirement is Ra 0.8. The customer’s demand was to improve tool life and reduce tool change times. Through the scientific combination of properly selected PCBN Insert Grade, advanced coating technology, and customized edge parameters, Worldia’s tooling solution achieved an average tool life of 108 pcs/edge, a 54.3% increase compared to the original solution.
◎ Worldia’s solution adopts the PNH2016 Insert Grade with excellent wear resistance and high temperature resistance, combined with CE coating technology to further enhance the insert’s high-temperature performance. Considering the requirements of continuous finish turning, 0.3 mm allowance, and Ra 0.8 roughness, customized wiper and chipbreaker PCBN inserts are used to avoid chip entanglement and achieve higher machining efficiency.
◎ Worldia’s customized tooling solution effectively solves the customer’s various machining challenges, improves tool life, reduces tool change times, increases machining efficiency, lowers tool costs, realizes a more economical tool replacement plan, and achieves superior replacement results.