Application Background
Automotive bevel gears are critical components in the transmission system, characterized by their conical tooth design that enables changes in direction of power transmission and torque transmission. They are typically used in automotive transmissions and differentials. To address the issues of short tool life and low efficiency in machining hardened steel components, Worldia has developed customized PCBN turning inserts, providing customers with mature, stable, economical, and highly efficient solutions.
Solution Analysis
◎ In this case, for the fine boring of the Φ25.2H7 inner bore of the bevel gear, where interrupted cutting occurs at the two pin holes, the adoption of Worldia’s customized PCBN inserts doubled tool life compared to the original solution. While maintaining the same feed per revolution, machining efficiency was increased by 1.38 times by raising the cutting speed, increasing the cutting depth, and eliminating one pass.
◎ Worldia’s customized PCBN inserts are tailored to the customer’s actual machining conditions, utilizing the PNH3019 Grade with excellent wear resistance and impact resistance. The edge is non-standard designed to balance edge strength and optimize cutting forces. Additionally, the C3 coating further enhances the insert’s high-temperature resistance and lubricity, reducing friction and achieving higher surface quality.
◎ Worldia’s customized superhard inserts provide tailor-made tooling solutions based on the customer’s actual machining conditions, which helps to improve tool life, increase machining efficiency, and reduce cutting tool cost.