This article share you some cbn grade for machhining cast iron,such as BN-K20, BNK30, BN-S300,ect. And also some aplication of cbn inserts machining cast iron materials. It includes the cutting condition, roughness and other parameters. And typical component include brake disc and brake drum, both of them are made of cast iron materials. And with cbn insert, they can be machined with high cutting speed and high efficiency.
CBN inserts for cast iron parts in automotive industry
1. CBN Inserts for cast iron parts in
Automotive industry
Zhengzhou Halnn Superhard Materials
Co.Ltd
2. Characteristics of CBN Tools
The excellent performance of CBN tools: High hardness, high heat resistance, high
chemical inertness.
● The high hardness of CBN Tool proved its excellent abrasive resistance.
● The high heat resistance of CBN Tool can meet the cutting condition of high speed and high
temperature.
● The high chemical inertness proved that CBN Tool has high antioxidant, it will not be
oxidized in 1000℃，and will not react with iron series metal in 1200 ℃. And it can be used
with high cutting speed, so that improved the processing efficiency.
● CBN Tools have good thermal conductivity, which can realse the heat near the insert tips,
and help improve the precision of the workpiece.
● CBN Tools will have low coefficient of friction, which will make the cutting tools have
excellent anti-sticking ability, and help improve the surface quality of the component.
3. Typical Application of Cast Iron Parts
Typical Component：
Brake Disc, Brake Drum (Roughing & Finishing)；
Engine flywheel (Roughing & Finishing)；
Boron cast iron engine cylinder liner (turning,
boring, Grooving)；
Cast iron engine block and Cylinder head (High
speed Milling)；
Gearbox housing(High speed Milling)；
Crankshaft, Camshaft (Roughing & Finishing)；
Pearlite ductile iron (High speed Cutting)
Also used for hard turning white iron
Materials：
Grey Iron
China Grade: HT200,HT250,HT300,ect.
Japan Grade: FC200FC250,FC300,ect
German Grade: GG20,GG25,GG30,ect
Ductile iron:
China Grade:QT600-3,QT700-2,QT800-2 QT900-2,
Japan Grade:FCD500 FCD600 FCD700 FCD800,
German Grade:GGG50 GGG60 GGG70 GGG80.
4.
5. Halnn CBN Insert Type
PCBN
Insert
Fastening pit and
Grooving Insert
Solid CBN Insert
Brazed PCBN
Insert
Coating
PCBN
6. Halnn CBN Grade for cast iron
CBN Grade Suited Materials
Machining
Type
Typical Application
BN-K1
Chilled Cast Iron
High chrome cast iron
High alloy cast iron
Roughing
Alloy cast iron rolls
Slurry pump (Impurity pump)
Abrasive resistant castings
BN-S300 Grey Cast Iron
Roughing
Finising
Brake Disc/Brake Drum
Cast Iron Engine
Cast Iron Gearbox
Cast iron cylinder liner
BN-K20 Grey Cast Iron
Semi-finishing
Finishing
Brake Disc/Brake Drum
Cast Iron Engine
Cast Iron Gearbox
BNK30
Grey Cast Iron
Iron series alloy
Semi-finishing
Finishing
Brake Disc/Brake Drum
Cast Iron Engine
Cast Iron Gearbox
BN-K10
Grey Cast Iron
Powder Metallurgy
Finishing
Valve seat ring
Engine cylinder bore
Powder metallurgy parts
11. Solutions for machining Brake Disc
Roughing Brake Disc: Common Insert Mateirals---BN-S300
Insert Model:CNMN120416、SNMN120712、CNMN120716
Finish turning brake disc: Common Insert Materials---BN-K20 or BNK30
Insert Model: SCGN0904 、CNGA120408、VNGA120408、WNGA080408、
TNGA160408
Noted: Both surface of the brake disc is parallel, the
Parallelism is about 0.06.
12. Processing parth of brake disc
1. Double-inserts performed at the same time
(Two methods: A-face double-inserts or AB-surface feed simultaneous.
13. Processing parth of brake
disc
2. Processing with one-sided Successively (as shown below)
18. Halnn CBN Insert with positioning pit
1.CBN Insert with positioning pit and through hole
It will be easy for positioning, especially for profiling and high speed cutting.
19. Halnn Wiper PCBN Insert
2.Wiper PCBN Insert：
(1) With same feeds, wiper insert can obtain better surface quality
(2) With same roughness requirements, wiper insert can use larger feeds, which can reduce
the time on each component, improve the efficiency；
Noted: It is Not suitable for profiling; suitable for machine tools and workpieces with high rigidity.
21. Halnn Coating PCBN Insert
3. Coating PCBN Insert：
The perfect combination of smooth coating and CBN base can achieve better cutting
performance and improve machining accuracy and life.
PCBN Performance
with Coating
PCBN Performance
without Coating
23. Two types Grooving Insert for Brake Disc
Brazed PCBN Grooving Insert,
the brazining layer is easily off,
which will lead to waste, so it
only suits for finishing process
or expanding the grooves .
Halnn BN-S300, Solid cbn
insert, can be used for both
roughing and expanding the
grooves.
Clipping method
of Halnn BN-S300
30. Grey Iron Application---Diesel engine cylinder liner
Materials: Boron cast iron, HB230-270
Selected Insert: BN-S300 SNMN120412 S02020,
ap=0.5mm, f=0.5mm/r, dry cutting
Material
Cutting Speed
Vc
Efficiency Tool Life
Coating
Carbide
Insert
480m/min
39 S
/pieces
26 pieces
Halnn BN-
S300
880m/min
21 S
/pieces
100
pieces
Processing efficiency improved about 1 times, and the tool life
improved 4 times, it will be more economic with Halnn cbn insert.
34. Halnn Customized Service:
PCD/PCBN Grooving Inserts and the corresponding tool holder, we can offer
customized service for you, you may need offer the information in the following form:
Insert Shape Item 内容
Blade Width W（mm）
Blade Radius R（mm）
Machining Materials
Groove Depth H（mm）
Machining Part
□ Cylindrical Groove
□ Internal Groove
□ Endsurface Groove
Tool Holder Length*Square（mm
）
35. Component:Automotive crankshaft damping
Materials:FC200,
Hardness:HB220
Insert:BNK30 CNGA120408 S01020
Tungsten Carbide:Vc=300m/min,ap=0.5mm，
Halnn CBN:Vc=650m/min,ap=0.5mm，
Tool Life improved 11.5 tims, and the tool
costs reduced about 35%!
The efficiency of Halnn cbn
insert will improve about 2
times than carbide insert,the
tool costs reduce about 35%!
Grey Iron application-Automotive Crankshaft damping
36. Grey Cast Iron application-Automotive clutch
plate
Selected Insert: CCGW09T304 S01025 BN-K20
Tool Life: 150 pieces/blade,
The roughness and brightness of the component will be
improved, and is suitable for machining castings.
38. New CBN Materail---BNK30 Application 1
Item Brake Disc Manufacturer
Material GG25(FC250)
Process Rough Machining
Selected Insert BNK30 CNGN120716
Cutting
Parameters
Vc=950m/min,Fr=0.7mm/r,
ap=2mm
Machinin Type Dry Cutting
With Same cutting parameters, the
tool life BNK30 is about 1.45 times
of other cbn insert.
39. New CBN Materail---BNK30 Application 2
Item Brake Disc Manufacturer
Materials GC250 (HT250)
Process Finishing, dry cutting
Hardness HB180~HB220
Selected Insert CNGN120412
Testing Performance
Insert Materails Halnn BNK30 Other International CBN
Cutting Condition Vc=1150,Fr=0.2,ap=0.25 Vc=880,Fr=0.2,ap=0.25
Roughness Ra1.6 Ra1.6
Tool life 640 475
Tool life
improve
about
35% !
Efficiency
improve
about
30%!
40. Performance advantages of Halnn
CBN Inserts machining cast iron
1.Comparing with other CNC insert, Halnn cbn insert can realize high speed cutting
and improve the process efficiency.
2.Comparing with coating carbide insert, the tool life can improve about 9~15 times,
the costs just about 7 times, cbn insert will be more economic.
3. The roughness can be improved with cbn insert.
4.Halnn Superhard, is one of the lead brand in China, not only can offer all ISO
cutting tools, but also can offer customized service.
Product characteristics：
41. Halnn Superhard, as the pioneer of superhard cutting tools in
China, make national Superhard Materials Key Laboratory and
Henan University of Science and technology as technical
support, have our own research center, focus on cbn cutting
tools and high grade diamond tools for machining brittle
and hard materials, have obvious advantages on most
industries, such as turning instead of grinding, high
hardness materials machining, heavy turning, high speed
machining, ect. At the same time, we have launched a series
of new cbn/pcd cutting tools and other material tools in 3C,
aerospace and Nuclear energy military field, depending on the
research center of Henan Superhard Materials Institute. Our
customers have covered many countries and areas, including
China Mainland, German, Italy, USA, Korea and other areas.
About Halnn
