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The tools with guide pads are well-suited for the precision machining of special holes. They offer high efficiency and stability while ensuring excellent machining accuracy and surface finish. Their applications span multiple industries, including automotive engine valve guide holes, crankshaft holes, camshaft holes, precision hydraulic valve holes in construction machinery, as well as guide sleeve holes in the mold-making industry.
These types of components often encounter the following special conditions during hole reaming:
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* Deep holes with high length-to-diameter ratios that require tight roundness and cylindricity tolerances；
* Partial holes finishing with high surface quality requirements；
* And stepped or interrupted holes with strict positional tolerance requirements.
In this case study, Worldia’s PCBN reamer with guide pads was applied to the machining of hydraulic valve holes in construction machinery. The tool not only significantly extended tool life and reduced the frequency of time-consuming tool adjustments, but also achieved domestic substitution of imported cutting tools—effectively lowering costs and enhancing efficiency for the customer.
Solution Analysis
◎ Worldia’s customized superhard tools can provide customers with special machining solutions for difficult-to-machine materials and components with special holes.
◎ In this case, Worldia’s customized guide pads tool with PCBN inserts was designed based on the customer’s material characteristics, actual machining conditions, and process requirements. It utilizes a carefully selected PCBN grade, combined with special cutting edge parameters and a C3 coating that enhances edge strength, helping the customer achieve a 166% increase in tool life.
◎ Compared with the original imported tooling solution, Worldia’s customized PCBN tool not only extends tool life but also delivers superior hole dimensional accuracy and machining quality. Moreover, it effectively reduces the frequency of complex guide pads tool adjustments and machine downtime, lowers operator labor intensity, improves machining efficiency, and helps the customer achieve localized replacement of imported cutting tools.
◎ In recent years, with the continuous rise in prices of domestic cobalt and tungsten raw materials, high-performance superhard tool solutions are gradually replacing high-cost imported alloy tools, and have become an inevitable development trend.