After rough machining, gears made of hardened steel 20MNCR5 undergo carburizing and quenching to improve surface hardness and mechanical properties. However, these processes often result in accelerated insert wear during finishing, affecting tool life and machining efficiency.
Moresuperhard's Solution
We provided the customer with an optimized CBN (Cubic Boron Nitride) insert solution, specifically designed for heavy-duty interrupted cutting of high-hardness materials. The upgraded tooling significantly extended service life and supported stable dry machining under demanding conditions.
Workpiece Overview
- Component: Gear
- Material: 20MNCR5 | Hardness: 60 HRC
Machining Environment
- Operation: CNC Turning, Rough Machining
- Cutting Type: Heavy Interruption, Dry Machining
- Insert Used: CNGA 120412 TH4-T TB8120
- Workpiece Diameter: 180 mm
Optimized Cutting Parameters
- Speed (S): 283 RPM
- Cutting Speed (VC): 160 m/min
- Feed (Fn): 0.12 mm/rev
- Depth of Cut (Ap): 0.5 mm
Features of the Moresuperhard's Optimized CBN Insert
- Reinforced cutting edge for superior impact resistance in intermittent cuts
- High-toughness substrate with excellent thermal stability, ideal for high-feed roughing of hardened steels
- Advanced thick coating for enhanced wear resistance and edge security under continuous dry machining
With the optimized CBN inserts, the customer achieved longer tool life, reduced downtime for tool changes, and maintained high machining efficiency—even under severe interrupted cutting conditions.
Partner with Us for Your Machining Challenges
Whether you are machining hardened gears or other high-strength components, we offer tailored cutting solutions that enhance performance, reduce cost per part, and maximize productivity. Contact us today to learn how we can optimize your machining process.
