Why Chip Control Matters in Hard Material Machining
Cubic Boron Nitride (CBN) inserts have revolutionized metalworking, offering unmatched hardness (3x harder than carbide) and thermal stability (>1,500°C) for machining hardened steels, cast irons, and superalloys. However, 68% of manufacturers report productivity losses due to chip entanglement – a critical challenge our engineers at Moresuperhard have solved through innovative chip breaker technology.
3 Root Causes of Chip Entanglement in CBN Machining
1. Material Behavior Under Extreme Conditions
At cutting speeds exceeding 300 m/min, ferrous chips reach 800-1,200°C, causing:
- Softening & increased ductility (flow stress ↓ by 40%)
- Formation of continuous ribbon chips (up to 2m long)
2. Inadequate Chip Evacuation Design
Flat-edge CBN inserts without chip breakers:
- Create uncontrolled chip flow paths
- Allow heat concentration (↑ 200°C vs. grooved designs)
3. Suboptimal Cutting Parameters
Common errors:
- Feed rates < 0.15 mm/rev → paper-thin chips
- DOC < 0.3mm → insufficient bending stress for fracture
Chip Breaker Technology: Precision Engineering for Uninterrupted Production
Proven Outcomes:
- 30% ↑ in machine utilization rates
- Ra < 0.4μm surface finish (meets aerospace polishing standards)
- 15% reduction in coolant consumption
Case Studies: Solving Real-World Chip Challenges
1. Automotive Cylinder Boring: From 30-Minute Downtime to Uninterrupted Production
Challenge: A Tier 1 supplier faced 12 daily stoppages cleaning cast iron (GG25) chips from flat CBN tools.
Solution: More superhard's chip breaker inserts with:
- 0.3mm nose radius for reduced notch wear
- 45° spiral groove geometry
Results:
- Continuous cutting ↑ from 0.5h → 2h
- 40% ↑ in daily output
2. Hardened Gear Shaft Finishing: Scrap Rate Cut from 8% to 0.5%
Material: 20MnCr5 (HRC 62)
Problem: Ribbon chips scratched surfaces (Ra 1.6μm), causing quality rejects.
Moresuperhard Solution:
- Precision-ground chip breaker
- Micro-hone edge prep
Outcome:
- Chip fragments < 3mm
- Ra 0.3μm achieved (mirror finish)
3. Aerospace Ti-6Al-4V Machining: Tool Life Quadrupled
Application: Wing spar pockets (intermittent cuts)
Failure Mode: 2m-long titanium chips caused vibration-induced tool fractures.
Our Innovation:
- Custom corrugated CB-Ti chip breaker
- Adaptive edge strengthening technology
Performance:
- Tool life: 50 → 200 parts
- Vibration amplitude ↓ 60%
Select a grinding CBN inserts with chip breaker and you will get:
- The processing efficiency is increased by 20%-30%
- Tool life is extended by more than 15%
- The workpiece surface roughness is reduced to Ra0.4μm or less
Whether cutting cast iron intermittently or finishing quenched steel, grinding CBN inserts with a chest-breaker is your secret weapon for improving your competitiveness. Contact us for a customized solution!
