CBN ‘sandwich’ insert brings large cost savings

WNT's next generation of Cubic Boron Nitride (CBN) inserts see a tungsten carbide base layer sandwiched by CBN.

While the method used to combine these two materials, brazing, is established technology, its use to create this sandwich effect for a CBN insert has not been possible up until now. The new, patented, manufacturing process used on the WNT inserts overcomes this problem, allowing multiple CBN 'edges' on a single insert. Of primary importance to the user is the price advantage that this system brings to CBN insert manufacture. For example, CNGA or DNGA style inserts now have four CBN cutting edges as opposed to the single cutting edge normally found on these shapes of insert. Similarly, WNGA style inserts now have six CBN cutting edges as opposed to one. The new process used by WNT dramatically reduces the labour content to such an extent that insert prices are typically 40 – 50 per cent of those currently on the market. As a result the cost per part is reduced by a considerable margin. For example*, if a traditional, single-edge insert can machine 100 parts at a cost of £35 per insert, the cost per part is £0.35. With the new WNT insert you could produce 400 parts at a cost of just £17.50, or £0.043 per part. Cost per component savings of this magnitude will have a significant impact on the profitability of many jobs that were previously being called into question. And, in the case of automotive production, where volumes are conventionally high the effect on the bottom line of a manufacturing company can be considerable. The new inserts are available in the most common CNGA, DNGA and WNGA insert styles, with a choice of eight different edge preparations for each style of insert. In addition, three grades of CBN are available, PBC15-S for grey cast iron, spheroidal-graphite cast-iron, superalloys, and sintered steels; PBC25-S for steels up to 65 HRc (uninterrupted cut); and PBC40-S for steels up to 65 HRc (interrupted cut). Because of the specific application of these inserts and to ensure the highest levels of productivity WNT (UK) would be happy to oversee initial cutting trials. * The insert costs and parts per edge in this example are for illustration purposes only. True tool life is subject to the specific application of the inserts.