PCD and PCBN Inserts for Machining Rolls

PCD and PCBN Inserts for Machining Rolls

Inserts Model: RNMN solid CBN, RCMX soilid CBN, PCD notching tools, PCD engraving tools

Application Fields of PCD inserts, solid cbn: high speed steel (HSS) roll, Ni-Cr alloy cast iron roll, chilled cast iron roll, threaded steel roll, cast iron rolls, cast steel rolls, tungsten carbide ring, forged steel cold Rolls

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Specification

PCD and PCBN Tools for Rolls Machining

Moresuperhard solid CBN inserts and PCD tools for machining high hardness rolls, cast iron roll, high-speed steel (HSS) roll, Ni-Cr alloy cast iron roll, chilled cast iron roll, threaded steel roll, cast iron rolls, cast steel rolls, tungsten carbide ring, forged steel cold Rolls. Due to its excellent properties, carbide rolls are widely used in the steel industry and their hardness is very high. For the machining of cemented carbide rolls, CBN/PCD Inserts can effectively replace the grinding process to improve production efficiency.

The roll is the main workpiece and tool that makes the metal continuously plastically deform on the rolling mill. The roll is mainly composed of three parts: roll body, roll neck and roll head. The roll is the intermediate part of the roll that actually participates in rolling the metal. Has smooth cylindrical or grooved surfaces. Rollers are almost universally used in nearly every manufacturing process in the world. The roller is the main part of the rolling machine, with the pressure which come from the rolling roller to roll the steel.

There are many classification methods of rolls,

- The material of the roller have : cast steel roller, case iron roller, forged roller.

- Product type, there are strip steel rolls, section steel rolls, wire rod rolls

- Position of the rolls in the rolling mill series, there are billet rolls, rough rolls, finishing rolls, etc.

- Product function, there are scale-breaking rollers, perforated rollers, leveling rollers, etc.

- Product material, there are hot rolls, cold rolls, etc.

- Type of rolling mill, it is divided into flat rolls and grooved rolls (it is used for rolling large, medium and small sections, wire rods and blooming billets. Grooves are engraved on the roll surface to shape the rolling stock), special roll

When processing mill rolls, especially processing large scale steel iron roll, it often has irregular surface, sand inclusion, holes and other problems. In order to solve the above problems we should choose What PCD and PCBN Inserts for Turning Rolls ?

- The tools materials for machining rolls include pcd inserts, pcbn cutting tools and solid cbn inserts, etc

- Solid CBN Insert is the hardest tool material for the processing ferrous metal materials and is the preferred tool for heavy duty cutting rolls. The high hardness rolls, Moresuperhard recommend the Solid CBN inserts which can be used for large margin cutting. Compared with the carbide cutting tools, the Solid CBN insert has performance stable, good production efficiency, and low production costs. Tungsten carbide ring is also called tungsten carbide alloy roll ring ( WC rolls or TC rolls), we process them with CBN and PCD Tools .

- Normally, CBN Inserts are generally used for rough turning tungsten carbide rolls which hardness ≤ HRA88. PCD Tools are mostly used for finish turning cylinder, chamfering and engraving.

pcd cbn cutting tools for machining roll

The specifications size of PCD tools, solid CBN inserts for machining roll

- Solid CBN inserts for Rolls Machining

As a PCBN inserts manufacturer and exporter in China, More Superhard's PCBN inserts have excellent performance in processing gray cast iron,nodular cast iron,hardened steel and material, sintered metal,and processing work piece surface is highly polished and very durable. Solid CBN iinserts rough machining high Ni-Cr alloy cast iron rolls, semi finishing chilled cast iron rolls, finish turning forged steel cold rolls, turning tungsten carbide rings and hss rolls, etc

RNMN CBN Inserts	Insert Type	Size Info
	Insert Type	L(mm)	I.C(mm)	S(mm)	R(mm)	D(mm)
	RNMN060400	6	6.35	4.76	0	-
	RNMN120700	12	12	7.94	0	-
	RNMN160700	16	16	7.94	0	-
	RNMN190700	19	19.05	7.94	0	-
	RNMN201000	20	20.000	10.00	0	-
	RNMN251000	25	25.400	10.00	0	-

RCGX Solid CBN	Insert Type	Size Info
	Insert Type	L(mm)	I.C(mm)	S(mm)	R(mm)	D(mm)
	RCGX060500	6.35	6.35	4.76	-	-
	RCGX090700	9.525	9.525	7.94	-	-
	RCGX120700	12.700	12.700	7.94	-	-
	RCGX151000	15.875	15.875	10.0	-	-
	RCGX191000	19.05	19.05	10.0	-	-

SNMN Solid PCBN Inserts	Insert Type	Size Info
	Insert Type	L(mm)	I.C(mm)	S(mm)	R(mm)	D(mm)
	SNMN090308	9.520	9.525	3.18	-	-
	SNMN090412	9.525	9.525	4.76	-	-
	SNMN120712	12.700	12.700	7.94	-	-
	SNMN150704	15.875	15.875	7.94	-	-
	SNMN150708	15.875	15.875	7.94	-	-
	SNMN201020	20	20	10	-	-

- PCD Notching Tools, PCD Boring Cutter for Roller

The PCD notching tools, pcd boring cutters are made by PCD blanks (E6) brazing on the tungsten carbide body. Most common is full face pcd notching tools. PCD boring tools are used for machining various of tungsten carbide rollers. PCD tips for carbide roller notching.

PCD notching inserts, Boring cutter	Size Info(mm)
	D	b	H	L	θ°
	2.5	0.5	1.6	5.2	80
	3	0.6	1.8	5.5	80
	4	0.7	2.3	7.83	70
	4	0.8	2.4	9.55	80
	4.5	0.9	2.75	10.7	80

PCD notching inserts, Boring cutter	Size Info(mm)
	D	b	H	L	θ°
	4	0.4	3.4	7.98	70
	4	0.8	3.4	9.68	80
	4.5	0.9	3.9	10.84	80

Tool Holder	Size Info(mm)
	D1	D2	D3	L1	L2
	4.5	2.5	16	5.22	35
	6	3.2	16	6.8	41
	8.8	5	16	9.5	56
	10.4	5	18	11	65
	13.5	6	18	14	65
	15.2	6	20	16	66

The cases of pcd tools, solid cbn inserts for machining rolls

1. RNMN120400 solid CBN inserts for machining roll

	Workpiece	Roll(Dia230mm)
	Processing location	cylindrical
	Hardness of workpiece	HRC84.5-85
	Code of CBN inserts	MCBN RNMN120400
	Cutting parameters	Vc=25m/min ap=0.6mm Fr=1.02mm/r
	Processing way	Dry grinding
CBN Material	CBN life	Result
More company CBN	> 5piece/blade	Normal wear and tear
Other company cutting tools	< 1piece/blade	edge breakage

When machining rolls, the grooving tool sometimes breaks, which is generally due to the following reasons:

Reason1.The tool holder and tool head are not well matched, the accuracy is not reached, and the tool is twisted during processing, resulting in tool fracture.

Reason2.The strength of the tool holder is not enough, and the alloy matrix of the PCD notching tools is too thin, so the strength and toughness are not enough, leading to fracture in the process of use.

Reason3.Unconventional fracture, for example, the positioning surface of the roller knife is not round, or there is a violent processing when processing.

For these reasons, we propose the following solutions:

Solution1.Control the precision of tool holder and tool head, pay attention to step by step when processing

Solution2.Enhance the strength of the tool and increase the thickness of the alloy matrix. If the customer has certain requirements for thickness, you can make the diamond part as thin as possible, the alloy matrix thicker to enhance the strength of the tool.

Solution3.The circular arc of the positioning surface of the PCD notching tools should be rounded. Not violent processing, should step by step.

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