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Hardened steel, with its high hardness, high strength, and high wear resistance, is widely used in transportation, energy, construction machinery, aerospace, and other fields. Machining hardened steel components is challenging, typically manifested as:
Tool life issues: The high hardness of hardened steel leads to rapid wear of the cutting edge.
Machining efficiency issues: Conventional tools cannot operate at high cutting parameters, resulting in low machining efficiency.
Machining quality issues: The high strength of the material generates large cutting forces, which can cause chatter. In continuous cutting conditions, poor chip control leads to chip wrapping, scratching the machined surface and affecting surface roughness.
Solution Analysis
◎In this case, the Worldia solution adopted a customized PCBN insert solution tailored to the machining allowance and condition of the hardened steel component, which increased tool life by 40% and doubled machining efficiency by increasing the cutting depth to achieve a single-pass cut while meeting machining requirements
◎In this case, based on the customer’s actual workpiece material and machining allowance, the Worldia solution selected the PNH2016 grade, which exhibits excellent red hardness and is suitable for heavy-depth turning of hardened steel. Additionally, to address chip control in heavy-allowance continuous turning, a non-standard chipbreaker and cutting edge design was employed, paired with a CE coating that offers high temperature resistance, wear resistance, and lubricity.
◎The Worldia customized tooling solution, based on the customer’s machining material and on-site conditions, significantly reduces machining costs, reduces tool changes and machine downtime, and thereby improves production efficiency while ensuring component quality. Faced with the dual pressures of market competition and rising raw material prices, we always adopt a customer-centric approach, providing practical and effective cost-control solutions to help customers reduce unit machining costs and enhance the competitiveness of their products.