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Strong Welding Continuous CBN Standard Insert

Cubic Boron Nitride (CBN)

  • PCBN has hardness and compressive strength close to that of diamond. The microhardness of PCBN powder is about8000–9000 HV, while the hardness of PCBN sintered bodies is 3000–5000 HV.
  • PCBN exhibits extremely high wear resistance: about 50 timesthat of cemented carbide tools, 30 times that of coated carbide tools, and 25 times that of ceramic tools. The cutting edge wear is minimal, resulting in ultra-long tool life and excellent machining quality.
  • Its thermal stability can reach up to 1400°C, and its oxidation resistance temperature can reach 1800°C. It does not chemically react with ferrous materials at temperatures above 1000°C. These properties make it particularly suitable for high-speed cutting of high-temperature alloys and hardened steels, with cutting speeds more than 3–5 timeshigher than those of cemented carbide tools.
  • PCBN has much higher thermal conductivity than high-speed steel and cemented carbide, and its friction coefficient is only 1–0.3, significantly lower than the 0.4–0.6of cemented carbide. These characteristics help reduce the temperature at the tool tip, prevent adhesion and built-up edge formation, reduce tool wear, and improve precision in high-speed finishing.
  • PCBN also has relatively high fracture toughness among superhard materials, allowing for a much higher feed rate before chipping compared to ceramic tools.
  • It delivers excellent surface quality, enabling complete machining in a single setup, achieving high dimensional and geometric accuracy while reducing machining time.
  • No coolant is required, chips are easy to handle, and the process is environmentally friendly.
  • Machining methods become more flexible, with lower equipment investment required.

 

Key Words：

PCD Cutting Tools, CBN Inserts, Polycrystalline Diamond Tools, PCBN Inserts, Hard Turning Tools, PCD End Mills, Superhard Materials

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Description

Introduction:

The integrally brazed CBN insert (Cubic Boron Nitride insert) is a high-performance cutting tool specifically engineered for hard turning applications of hardened steel (55–65 HRC), bearing steel, and cast iron. Utilizing advanced vacuum brazing technology, the CBN cutting edge is permanently bonded to a carbide substrate, delivering superior bonding strength, high thermal resistance, and excellent wear performance in both continuous and interrupted cutting.

Compared to traditional clamped CBN inserts, the brazed CBN insert offers enhanced rigidity and vibration resistance, ensuring stable machining, improved surface finish, and consistent dimensional accuracy. The optimized edge geometry with honed and chamfered cutting edges effectively reduces chipping, increases edge strength, and extends tool life under high-speed cutting conditions.

This CBN turning insert is ideal for dry machining and high-speed finishing, significantly reducing cycle time and tooling cost per part. It is widely used in CNC lathes for machining hardened components such as automotive gears, bearing rings, rollers, and hardened shafts.

As a reliable solution for replacing grinding processes, the brazed CBN insert improves productivity while maintaining high precision and surface integrity. It is an excellent choice for automotive, aerospace, and precision engineering industries seeking cost-effective and stable hard machining solutions.

  1. Metallurgical Bonding Mechanism at the Interface

The brazed integral structure forms a true metallurgical bond between the CBN compact and the carbide substrate, as opposed to purely mechanical retention. This significantly enhances interfacial shear strength and suppresses crack initiation and propagation under cyclic mechanical and thermal loading.

  1. Thermal Conductivity and Heat Dissipation Efficiency

The continuous bonding interface reduces thermal contact resistance, enabling efficient heat transfer from the cutting edge to the substrate. This mitigates localized thermal accumulation, thereby improving resistance to thermal softening and oxidation wear during high-speed or dry cutting.

  1. Mechanical Integrity and Structural Rigidity

The monolithic configuration eliminates compliance typically associated with clamped or tipped tools. This results in higher system stiffness, reduced vibration amplitude, and improved resistance to edge micro-fracture, especially in interrupted cutting conditions.

  1. Wear Mechanisms and Tool Life Behavior

CBN exhibits exceptional resistance to abrasive wear, adhesive wear, and diffusion wear when machining ferrous materials. The brazed design ensures stable load transfer, leading to predictable flank wear progression and extended tool life under high hardness machining conditions (HRC 45-65).

  1. Cutting Edge Stability and Dimensional Control

The rigid bonding and high hardness of CBN enable superior edge retention, minimizing edge rounding and plastic deformation. This ensures tight dimensional tolerances and improved surface integrity over prolonged machining cycles.

  1. Process Substitution Capability

Brazed CBN inserts enable hard turning as a viable alternative to grinding, offering reduced cycle times, lower capital investment, and improved process flexibility while maintaining comparable surface finish and geometric accuracy.

  1. Reliability in Automated and High-Volume Production

The consistency of the brazing process ensures uniform tool performance, reducing tool-to-tool variability and enhancing predictability in CNC and automated production lines.

  1. Life-Cycle Cost Efficiency

Despite higher initial tooling cost, the significantly extended tool life, reduced tool change frequency, and minimized downtime result in a lower cost per part in mass production environments.

 

Multi-edge Insert

 

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