Application Background
Cutoff and grooving are common and widely used machining processes, applied in automotive, construction machinery, civil aviation, energy and other industries.
Grooving differs from general turning in the following aspects:
■ Grooving usually generates larger cutting force, which easily causes vibration and impairs machining quality;
■ Restricted by functions and structures, parting inserts and their clamping systems feature low rigidity, resulting in short tool life;
■ Chip breaking and evacuation in grooving and cutoff operations. Chip entanglement frequently occurs, shortening tool service life and deteriorating finished surface quality.
As an integrated cutting tool manufacturer focusing on superhard tools, Worldia provides PCBN and PCD tool solutions for cutoff and grooving of hardened steel, cast iron, powder metallurgy,non-ferrous metals and hard alloys.
Solution Analysis
◎ The customer’s workpiece is a new energy vehicle motor shaft with mass production volume and high material hardness. Strict requirements are imposed on groove dimensional accuracy and machining quality, including radii on both groove edge and bottom, and burr-free groove surface. Worldia’s coated standard PCBN grooving insert delivers a 74% longer tool life compared to the original solution.
◎ Tailored to the customer’s actual requirements including workpiece material, machining dimensions and burr-free grooves, Worldia adopts C2-coated standard PCBN grooving inserts with PN409 grade, which boasts excellent toughness and chipping resistance. The customized edge geometry maintains sharp cutting edges while optimizing cutting force, extending insert life and guaranteeing superior workpiece surface quality.
◎ Worldia superhard grooving tools cover a full range of standardized sizes for common workpiece materials, enabling easy selection and fast delivery. The specially designed positioning clamping structure delivers firmer clamping and higher rigidity. Customized products are also available to fulfill special machining demands, covering full processes such as parting, external grooving, face grooving, internal grooving and thread turning.