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The FUJKE CBN tool brings a new era in machining with its "car-generation grinding" process, which is not only efficient but also eco-friendly. But what exactly is this so-called "car-generation grinding"? And why is it becoming a game-changer in the manufacturing industry?
Car-generation grinding refers to the use of CBN (Cubic Boron Nitride) or ceramic tools to machine hardened materials. This advanced method allows for the cutting of hardened steel, gray cast iron, ductile iron, powder metallurgy, and other special materials that were once difficult to process.
So, what makes car-generation grinding stand out? Here are some key benefits:
1. **Cost-Effective**: Using CBN tools is significantly cheaper than traditional grinding wheels—often just a quarter of the cost.
2. **Flexible Setup**: Unlike conventional grinding, which requires specialized machines and fixtures, car-generation grinding can be done on existing NC or CNC turning centers, reducing the need for additional equipment.
3. **High Productivity**: CBN cutters operate at high speeds, boosting productivity and saving valuable time during the machining process.
FUJKE’s integrated polycrystalline (FBN) cutters offer exceptional precision, achieving a machining size accuracy of ±0.01mm and surface roughness as low as Ra0.8–1.6μm. This means less investment in grinding machines and fewer setups, leading to shorter production cycles. Plus, the process supports dry cutting, which saves energy and reduces environmental impact. It’s a true green solution for hard machining, widely adopted in industries like gear and bearing manufacturing.
With the cost of CBN tools dropping significantly in recent years, car-generation grinding has become more accessible. The cost savings go beyond just the tools—they extend to the overall manufacturing cost per part. With long tool life and low per-cutting cost, CBN offers the most economical option for hard machining.
Another major advantage is environmental sustainability. Traditional grinding produces a mix of abrasive waste and coolant, which is hard to recycle and can harm the environment. In contrast, the waste from car-generation grinding is often reusable, making it a more sustainable choice.
Factory space is another important consideration. Grinding wheels are large and bulky, taking up significant storage space. CBN tools, on the other hand, are compact and can be used directly on existing machines, eliminating the need for extra equipment and saving valuable floor space.
The rapid growth of car-generation grinding is driven by advancements in CBN tool technology. In the early 1990s, only a few CBN tools were available for such applications. Today, the number of options has grown tenfold. Cutting speeds have also improved dramatically—while the maximum speed for cast iron was around 152m/min back then, it now reaches up to 1524m/min. For hard steels, typical cutting speeds range from 90 to 150m/min, with feed rates between 0.05–0.2mm/rev and depths of cut from 0.1–0.5mm.
Additionally, the versatility of CBN has expanded. Once limited to certain types of materials, it now works well with a wide range of hardness levels and even brittle workpieces, opening up new possibilities in modern manufacturing.