by Ashwin Murali, Shi Chen and Igor Kaufmann
Abstract
Metalworking industry is looking for increase in productivity and maintaining costs per part. One of the most effective methods is the drastic increase of cutting speed by use of Polycrystalline Cubic Boron Nitride (PCBN). The challenge in cast iron machining with ISO/ANSI inserts are high tooling costs and insufficient stability of the insert due to form locked clamping mechanism. The paper presents Beyond shield: an innovative clamping mechanism which provides better rigidity and less movement of the insert, combining with a new designed PCBN inserts shape which results in lower grinding, lower manufacturing time and eventually lower cost.
1-minute pitch
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How critical are the tolerances between the insert and the insert receiving pocket of the tool holder? What happens if they do not match accurately?
Is there any size limitations on the cutting tool inserts? and what is the minimum and maximum sizes that can be accommodated using the developed tool holder?
I should be interested in learning about the possible use PCBN inserts for the machining of Ni based superalloys for aerospace applications (for example Inconel 718). For Grey iron, you used a cutting speed over 1000 m/min. Do you have an idea of the possible increase of cutting speed for Nickel superalloys from the present values of 40-50 m/min in order to make PCBN inserts cost effective for aerospace component machining?
Very interesting work, is there any limitations on the force applied to the clamp?