Application Background

Worldia custom PCBN cutting tools are optimized solutions tailored to customers’ specific workpiece materials, machining requirements and operating conditions, with optimized matching of insert grade, insert geometry and cutting parameters. The formulation of machining solutions requires consideration of the following aspects:
■ Workpiece material: Define the applicable scope of insert grades for hardened steel, cast iron and powder metallurgy to select proper inserts;
■ Machining requirements: Including dimensional tolerance, geometric tolerance, surface roughness and machining cycle time;
■ Machining conditions: Including machining allowance, continuous/interrupted cut, machine rigidity and cooling method.

Solution Analysis

🔶 The customer intended to extend tool life and lower machining costs. The process involves continuous & interrupted turning on the Φ36 inner bore and Φ58 end face of the stator end plate with a 0.09mm machining allowance. By adopting custom PCBN inserts, Worldia achieves a 28% longer tool life under identical cutting parameters.
🔶 Compared with the original solution, customized for the process characteristics, Worldia selects PN409 Insert Grade with balanced wear resistance and toughness. The insert adopts non-standard edge geometry optimized for finishing processes, combined with C2 coating to boost anti-wear performance.
🔶 Worldia custom superhard insert series is developed according to customers’ component features and actual machining conditions. Starting from customer demands, we help users extend tool life, reduce tool change frequency and downtime, improve machine utilization, reduce tool expenses and optimize machining processes, so as to strengthen customers’ product competitiveness.

Data Source: Tool Test Report of Precision Tool Technology Department of Beijing Worldia Diamond Tools CO., Ltd.

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📌www.worldia-tools.com
📍Or send inquries to: info@worldia-tools.com