Precision Machining Solutions for Hardened Steel Components
This case study demonstrates the successful application of our CBN inserts in demanding machining operations on high-hardness materials. Each scenario details specific insert grades, workpieces, and optimized cutting parameters for maximum efficiency.
Case 1: Gear Face Finishing (58-60 HRC)
Workpiece: 20MNCR5 Gear Steel
Insert: CNGA 120408 KB2000-CBN inserts
Operation: Fine finishing of gear faces
Conditions:
Depth of Cut (Ap): 0.1 mm
Feed Rate (f): 0.07 mm/rev
Suitable for both continuous cutting and light interrupted cuts
Result: Achieved high surface finish requirements on critical gear components.
Case 2: Automotive Shaft OD Finishing (62 HRC)
Workpiece: 20MNCR5 Audi Car Shaft
Insert: CNGA 120412 TH4 BC8120-CBN inserts
Operation: External diameter (OD) finishing
Conditions:
Depth of Cut (Ap): 0.4 mm
Feed Rate (f): 0.14 mm/rev
Speed (S): 1400 RPM
Light interrupted cutting conditions
Result: Efficient precision machining on high-hardness shafts under light interruption.
Case 3: Gear Steel OD Roughing (55-60 HRC)
Workpiece: 20MNCR6 Gear Steel
Insert: CNGA 120408-CBN inserts
Operation: OD rough machining
Conditions:
Depth of Cut (Ap): 1.0 mm
Heavy interrupted cutting
Dry machining environment
Result: Reliable material removal under aggressive roughing and heavy interruption.
Case 4: Bearing Steel Turning (65 HRC)
Workpiece: 100CR6 Bearing Steel
Insert: DNGA 150408-CBN inserts
Operation: Combined OD and face turning
Conditions:
Depth of Cut (Ap): 0.3 - 0.5 mm
Heavy interrupted cutting
Tight tolerance requirement: 20 microns
Result: High-precision machining achieved on hardened bearing components under severe interruption.
Case 5: Bearing Steel ID Turning (66 HRC)
Workpiece: Bearing Steel
Insert: DNGA 150408-CBN inserts
Operation: Internal Diameter (ID) turning
Conditions:
Depth of Cut (Ap): 0.8 - 1.0 mm
Light interrupted the cutting
Result: Effective ID machining solution for high-hardness bearing materials.
Case 6: Bearing Steel OD Roughing (65 HRC)
Workpiece: Bearing Steel
Insert: TNGA 160412-CBN inserts
Operation: OD rough machining
Conditions:
Depth of Cut (Ap): 1.0 - 1.20 mm
Continuous cutting
Wet coolant application
Result: Stable and productive roughing operation on bearing steel under continuous cuts.
Technical Takeaways:
Material Expertise: Proven performance on hardened gear steels (20MNCR5/20MNCR6) and bearing steels (100CR6) up to 66 HRC.
Adaptability: Specific insert grades (CNGA, DNGA, TNGA) optimized for facing, OD finishing, OD roughing, and ID turning.
Robustness: Reliable operation in demanding conditions, including heavy interrupted cuts, light interruption, and dry machining.
Precision Capability: Achieves tight tolerances (e.g., 20 microns) in high-hardness finishing applications.
Optimize your hard turning operations with our engineered CBN inserts solutions. Contact our technical team for application-specific recommendations.
