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High efficient hard machining with new and innovative monolithic CBN end mills

Presentation held at XIVth International Conference on High Speed Machining 2018; Productivity, Quality and Digitalization, 17-18 April 2018, San Sebastian
Hocheffiziente Hartzerspanung mit neuen und innovativen, monolithischen CBN-Werkzeugen
: Eckert, Udo; Schneider, Jörg; Edelmann, Jan; Putz, Matthias

Präsentation urn:nbn:de:0011-n-4945237 (1.6 MByte PDF)
MD5 Fingerprint: 4356960a3de3037e7dc3ad288e3508b4
Erstellt am: 30.5.2018

2018, 16 Folien
International Conference on High Speed Machining <14, 2018, San Sebastian>
Vortrag, Elektronische Publikation
Fraunhofer IWU ()
cutting tool; cubic boron nitride (cBN); hard machining; micro machining; lubrication; finishing

A new approach for high efficient hard machining is presented based on new and innovative monolithic CBN end mills in the millimetre diameter range. Compared to tungsten carbide tools, the use of CBN end mills offers not only 5-10 times increase in tool life but also a doubled material removal rate based on higher cutting speeds and feed rates. Furthermore the reliable and repeatable use of the CBN cutting material offers potentials to substitute conventional finish machining processes. Nevertheless monolithic CBN end mills in the diameter range of 1 mm to 10 mm are commercially not available. In the lower diameter range appropriate tools are state of the art, in higher diameters CBN inserts for cutter heads could be used in serial production. Especially in the intermediate tool diameter range, which is often required in tool and die making industries, tools and adapted machining technologies are unavailable. The paper presents intermediate results of a funded R&D project with focus on development of new tool concepts for monolithic CBN end mills in the diameter range of 1 mm to 10 mm. Research on adapted cutting technologies and machining strategies with adequate cutting parameters are in focus of the project as well as investigations on new process chains for efficient hard machining operations in tool and die making industries. An additional target is the development of cooling and lubrication strategies adapted to the requirements in CBN machining. Therefore basic research on application oriented demonstration workpieces will be presented and compared in relation to geometrical accuracy and surface quality. Especially the design, surface functionalization and different geometrical dimensions of the single structure features (e.g. fins, channels, sharp edges and slopes, deep pockets) on the demonstration workpieces require different approaches during hard machining of these workpieces.