A customer experienced chipping issues while using PCD inserts to groove cemented carbide rolls during rough machining. Upon analysis, we found that the rough machining process was a significant factor and recommended testing with CBN inserts as an alternative.
Problem Analysis
In theory, PCD inserts can be used for grooving cemented carbide rolls. However, their performance depends heavily on specific working conditions. The key factors affecting insert selection are as follows:
1. New Groove vs. Repair Processing
- New Groove Processing: When machining a new groove, PCD inserts typically perform well with minimal issues.
- Repair Processing: In cases where the rolls already have grooves, the process involves strong intermittent cutting forces. This can lead to the chipping of PCD inserts due to the high-impact stress.
2. Working Conditions and Machining Allowance
- Poor Conditions, Large Allowance: Under rough machining conditions with a large machining allowance, the cutting forces and impacts are higher. In such cases, CBN inserts are recommended for their superior toughness and impact resistance.
- Good Conditions, Fine Machining: For finishing operations under stable conditions, PCD inserts are ideal for achieving higher precision and surface quality.
Solutions and Recommendations
Based on the customer's requirements and working conditions, we recommend the following:
1. For Rough Machining:
Use CBN inserts to handle the high-impact forces during rough machining. This helps to prevent chipping and ensures longer tool life.
2. For Finishing Operations:
When machining allowances are small and conditions are stable, opt for **PCD inserts** to achieve superior surface finish and dimensional accuracy.
Conclusion
The choice between PCD and CBN inserts for machining cemented carbide rolls depends on the specific application and working conditions. Proper tool selection can enhance efficiency and reduce tooling costs:
- CBN Inserts: Best suited for rough machining and intermittent cutting due to their impact resistance.
- PCD Inserts: Recommended for finishing operations to achieve high precision and surface quality.
If you have any questions about tool selection or process optimization, feel free to contact our technical team. We’re here to provide professional advice and support.
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