VNGA160404 & TNGA160408 PCBN Inserts: Mirror Finish on SUJ2 HRC 60-63
From Grinding to Hard Turning: Achieving Mirror Finish on SUJ2 (HRC 60-63) with CD6100 Grade PCBN Inserts
Project Background & Customer Challenges
In the precision manufacturing industry, machining high-hardness materials has long been a bottleneck for efficiency and cost control. Recently, one of our partners faced a significant challenge while processing a batch of SUJ2 (Bearing Steel) components. These parts, after heat treatment, reached a consistent hardness of HRC 60-63.
The customer’s original process involved "Rough Turning + Grinding." However, the grinding phase was extremely time-consuming, led to high equipment occupancy, and struggled to meet increasing delivery demands. The objective was clear: implement a "Turn-to-Grind" strategy using high-performance PCBN (Polycrystalline Cubic Boron Nitride) tools to achieve a mirror-like surface finish directly on the lathe.
2. Case Details: Precision Alignment of Model and Grade
As a professional cutting tool supplier, we believe that the Tool Model determines compatibility, but the Material Grade determines success. For this SUJ2 HRC 60-63 application, we didn't just provide standard specifications; we engineered a solution centered on the CD6100 Grade:
Workpiece Material: SUJ2 Bearing Steel
Hardness Range: HRC 60-63 (Quenched & Hardened)
Requirement: Total replacement of the grinding process with a mirror-finish output.
3. Technical Specifications & Parameter Guidelines
Based on the different geometries required (profiling, longitudinal turning, and deep bores), we provided three specific configurations using the CD6100 Grade:
Expert Note: The CD6100 Grade is specifically engineered for HRC 60+ hardened steel. Its unique ceramic binder effectively inhibits chemical diffusion wear at high temperatures—the "secret weapon" for achieving that mirror finish.
4. Application Showcase & Image Description
Image Description:
Center Focus: Displays the finished SUJ2 components processed with the VNGA160404-2S (CD6100). The surface exhibits a flawless mirror reflection, proving the total elimination of the grinding stage.
Background: Shows the Full-Face PCBN series used in this case. The seamless brazing surface and precision-ground edges are the foundation for stable, chip-free performance.
5. Results & Performance Summary
By implementing this "Model + Grade" optimized solution, our customer achieved remarkable results in their production line:
1.Superior Surface Quality: The measured surface roughness (Ra) reached grinding-level standards, producing a mirror finish that passed strict bearing-grade inspections.
2.Efficiency Doubled: By successfully eliminating the grinding cycle, the total production time per piece was reduced by approximately 45%, significantly unlocking factory capacity.
3.Cost Optimization: While PCBN inserts have a higher initial cost than carbide, the extended tool life of the CD6100 Grade and the multi-edge design (TNGA 6-edge / VNGA 4-edge) reduced the total cost per part by over 20%.
Final Verdict: In the world of high-hardness machining, the Model is what you search for, but our expert Grade matching is what delivers the results you need.
