Roll processing involves working with large, high-hardness materials such as chilled cast iron, alloy cast iron, high-speed steel, forged steel, and tungsten steel. Due to their substantial hardness and machining allowance, these materials significantly demand cutting tools. This article explores our company's PCBN (Polycrystalline Cubic Boron Nitride) tool solutions for various roll materials, highlighting how they can boost roll machining efficiency and reduce tool wear.
Roll processing requirements for tools:
1. High Hardness, Wear Resistance, and Heat Resistance
Roll hardness is typically above HSD55. Our company has developed PCBN blades with high CBN content to address this requirement, which are produced using advanced manufacturing techniques. This ensures superior wear resistance, thermal stability, and red hardness at high temperatures, allowing our tools to easily machine workpieces with hardness above HSD55. Our PCBN tools exhibit 3–5 times longer tool life than ceramic tools, significantly reducing wear and chipping under high-temperature conditions.
2. Exceptional Impact Resistance
Large rolls, especially cast-formed ones, often contain casting defects like particles, sand inclusions, and pores. These imperfections make conventional tools prone to chipping due to poor impact resistance. Our solid PCBN blades have excellent impact resistance, supporting both continuous and interrupted cutting without chipping or breaking. They are more than ten times more durable than ceramic tools and serve as a reliable replacement for imported tools. Additionally, our blades feature positioning grooves for secure clamping under challenging processing conditions.
3. Deep Cutting Capability
Roll blanks generally have a substantial machining allowance per side, requiring tools capable of deep cuts. Conventional tools are limited in cutting depth, impacting efficiency. Our PCBN blades for rough machining allow cutting depths of up to one-third of the blade edge, facilitating a high material removal rate. The multi-edge design further maximizes blade utilization, reducing tool changeovers.
4. High Efficiency
PCBN retains its hardness at temperatures up to 1200°C, allowing for higher cutting speeds in roll machining. Our PCBN blades provide high-speed cutting, large cutting volumes, and excellent surface finish. For high-nickel-chromium cast iron rolls with HSD78 hardness, our PCBN tools achieve single-side cutting depths of approximately 7 mm, with a feed rate of 0.8–1.2 mm/r.
Recommended PCBN Cutting Parameters for Various Roll Materials
Additional Tips for Maximizing Roll Processing Efficiency
Selecting suitable tools, optimizing tool structure, controlling cutting parameters, ensuring effective lubrication and cooling, and regularly replacing tools are essential to enhancing roll processing efficiency. Considering these factors and adopting suitable solutions can significantly improve machining quality and efficiency.
From roughing to finishing and continuous to interrupted cutting, our PCBN tools handle high cutting loads, achieve extended tool life, and substantially boost machining efficiency. Supported by our advanced manufacturing technology and dedicated technical service team, we provide a strong after-sales guarantee for our products.
