(5) With the development of tool material technology and the increasingly innovative manufacturing process, the material and toughness of PCBN tools have undergone great changes. The new PCBN tool has revolutionized the number of grades that lacked toughness in the early days. Many new developments have taken place in the design and use of PCBN tools. PCBN tools can more widely meet the requirements of special workpiece material processing, improve processing performance and expand the application range. For example, the automotive industry uses the newly developed PCBN integral thick blade to effectively cut hard-to-machine hard cast iron alloys that were previously only ground. At present, PCBN tools have been widely used in machining fields such as turning, milling and boring.
Prospects for PCBN tools in the 21st century
(1) As one of the major replacement tools in the 21st century, PCBN tools account for a larger proportion of the total use of tools in industrialized countries. More and more difficult materials are being processed, and the future of PCBN, the main tool material for cutting difficult-to-machine materials, is bright. For example, the machining of the main frame of the aircraft (ultra-high-strength steel) is very difficult, and the processing of PCBN tools is one direction. In addition, the high-temperature alloy parts on the aero-engine are difficult to process. At present, the effect of machining with CBN tools is not very satisfactory. This is obviously a very attractive research project. Once it breaks, it will bring the high-temperature alloy processing field. New changes.
(2) With the development of materials science and manufacturing technology, a new generation of difficult-to-machine materials such as high-chromium steel, high-nickel steel, high-speed steel, tungsten carbide, ceramics, etc., has raised new issues for modern machining, and PCBN tools have become The most competitive tool for cutting difficult materials.
According to statistics, in China, the amount of cemented carbide tools accounts for 60% of the total tools, and high-speed steel accounts for 30% to 40%. PCBN tools currently account for a very small proportion. In China, the annual production capacity of high-speed steel is 50,000 to 60,000 tons, accounting for 1/4 to 1/3 of the world. The annual production of cemented carbide is 12,500 tons, accounting for 40% of the world. A large amount of tungsten is used, and high-speed steel is also used for tungsten. Although China is a tungsten-producing country (accounting for 80% of the world), tungsten will gradually dry out after 50 years, and CBN raw materials do not contain tungsten. It can be said that the raw material of PCBN is Inexhaustible, therefore, the development of PCBN has very important strategic significance.
(3) By further improving the manufacturing process of PCBN, the manufacturing cost can be reduced; at the same time, the binder phase material of PCBN and its ratio with the hard phase can be further adjusted, the hard phase can be reduced, the binder phase fraction can be increased, and the PCBN can be made. The toughness is further improved, reducing the hardness from HV8000 to HV4000~5000 (this hardness is still more than 1 times the hardness of cemented carbide tools), changing the brittle weakness of PCBN cutters, making it harder and harder to process than HRC45. Materials also have the advantage of greatly expanding the range of PCBN tools.
(4) In the first half of the 20th century, the appearance of cemented carbide replaced 1/2 of high-speed steel, making the field of machining a new look; in the 21st century, PCBN tools will have great development, and the application prospects are limitless. Even if you replace a part (such as 1/5~1/4) of carbide tools and ceramic tools, there will be quite amazing revolutionary changes.
School of Mechanical and vehicles of the Beijing Institute of Technology: Zhang Jingying in Kai Xun
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