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Fig 239: (a) Synthesis of cubic boron nitride [32] using magnesium as a catalyst (b) An insert consisting of cubic
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boron nitride and tungsten carbide compact Only four cutting edges are available (c) A micrograph of cubic boron nitride on a WC+Co substrate (Etchant: Murakami)[3]
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A CBN tool possesses various characteristics, one of which is its extremely high hardness at room temperature (Knoop s hardness of 39 GPa), and it consists of single-crystal CBNs in a binder phase A range of CBN materials may be obtained determined by varying the CBN content, CBN grain size and binder phase materials According to Wentorf et al [43], a single-crystal cubic boron nitride is formed by conversion from a hexagonal boron nitride crystal It has the structure of zincblende, comprising two interpenetrating face centred cubic lattices, one of boron and the other of nitrogen Figure 240 shows the microstructures of the CBN materials used by Harris et al [44],
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Fig 240: Microstructures of the PCBN materials [44]
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when investigating the effect of temperature on the hardness of polycrystalline cubic boron nitride cutting tool materials Among all materials, Cubic Boron Nitride is known as the second hardest material second only to that of diamond It has excellent wear durability, which is also second only to diamond It also has a considerably high hot hardness, chemical inertness with respect to ferrous materials, good thermal resistance and a high coefficient of thermal conductivity, its cutting property under high temperature therefore being better than that of diamond Since it has a good thermal stability, it is unlikely to react chemically with the workpiece under high thermal conditions As a result, in manufacturing, CBN tools are mainly used in the processing of hard-to-machine materials Table 29 shows the comparison of properties of Polycrystalline Cubic Boron Nitride (PCBN) and other cutting tool materials Table 29 Comparison of properties of polycrystalline cubic boron nitride and other tool materials [44]
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Carbide WC + 6% Co 148 13 620 250 022 2,300 5,900 12 5 95 Polycrystalline Polycrystalline Natural diamond cubic boron diamond (PCD) nitride (PCBN) 343 50 925 426 0086 >2,800 4,740 689 38 120 312 28 680 279 022 600 800 3,800 10 49 100 352 57 104 1141 553 007 700 1,700 8,580 34 35 500 2000
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Density, g/cm3 Knoop s Hardness, Gpa Young s Modulus, E, Gpa Modulus of Rigidity, G Gpa Poisson s Ratio, v Transverse Rupture Strength, Mpa Compressive Strength, Mpa Fracture Toughness, KIC, MN/m3/2 Thermal Expansion Coefficient, c, 10 6/K Thermal Conductivity, W/mK
In general, a CBN insert is used in bulk form as a tool insert or as brazed segments in combination with tool bodies, usually with a carbide substrate At present, the commercial use of CBN tools mostly pertains to hard turning or boring processes, although they have very limited application in milling operations due to their high hardness but inferior toughness, which makes them less suitable for heavy cutting operations or for milling Since CBN is a relatively new cutting tool material, information on its cutting characteristics, such as tool life, cutting forces, wear and surface quality of the processed workpiece, is still in its infancy
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The CBN tool wear has been frequently studied Due to their great hardness and abrasive resistance, CBN tools generally have a greater wear resistance than do conventional tool materials such as carbides, cermets, and ceramics CBN tools can be roughly categorized into two groups: high CBN content (~ 90 vol %) with a metallic binder, and a low CBN content (50 70 vol %) with a ceramic as a major binder The commercialization of cubic boron nitride (CBN) tools has generated great interest in hard machining technology for today s industrial production and scientific research Hard turning encompasses a relatively wide range of workpiece hardness values (45 70 HRC) The hardened workpiece surface has an abrasive effect on the tool material, and the high temperatures of the cutting edge generate diffusion between the tool and the chip Hard turning requires high-performance cutting tools and extremely rigid machine tools Matsumoto and Diniz [45] have found that it was possible to achieve a surface and dimensional quality similar to that of ground components even when the machining was performed on a conventional lathe when turning several AISI 52100 hardened steel work pieces (60 HRC) with ceramic and PCBN cutting tools Chou and Evans [46] have conducted a study on CBN tool wear in interrupted hard cutting, and their results showed significantly different wear characteristics between high and low CBN content tools The tool life of CBN-L is optimized at a medium cutting speed On the other hand, CBN-H shows a monotonic decrease of tool life with increasing cutting speeds
Fig 241: Tool life of CBN tools at different cutting speeds [46]
Based on the results of Diniz and Gomes [47], the main problem, which caused the tool life to end, was flank and crater wear for the high CBN content tool and chipping/breakage for the low CBN content tool In many applications, the cutting of ferrous materials in their hardened conditions can replace grinding to give a significant cost saving and increase in productivity CBN tools are widely used in the manufacturing industry for cutting various hard materials: high-speed steels, tool steels, die steels,
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