Traditional grinding processes, while accurate, are inefficient and costly. At this point, CBN tools are becoming the ideal choice to replace grinding and improve efficiency.
I. Why Choose Berlt PCBN Tools for Machining Wind Turbine Bearings?
· Can replace grinding, reducing costs and shortening cycle times: PCBN hard turning can achieve dimensions and surface quality close to grinding in a single setup, reducing or eliminating grinding steps, thereby significantly lowering machining costs and cycle times.
· Suitable for machining high-hardness materials: Bearing steel after heat treatment has high hardness and contains carbon and carbides. Conventional carbide tools have short tool life, whereas PCBN tools can maintain tool tip life and tool strength even at high cutting temperatures.
· Dimensional stability and green machining: PCBN turning ensures dimensional consistency in mass production and allows for dry cutting or minimum coolant, which is beneficial for environmental protection and workpiece cleanliness.
II. Typical Challenges in Wind Turbine Bearing Machining
· Interrupted cutting and oil hole/groove structures: Bearing oil grooves, oil holes, raceways, etc., cause interrupted cutting and impact loads, testing the tool's chipping resistance and impact toughness.
· Large workpiece dimensions and clamping deformation: Large inner and outer rings are prone to thermal deformation and unstable clamping during turning, requiring suitable fixtures and cutting sequences.
· High requirements for surface integrity: Raceway arc accuracy and surface roughness requirements demand high precision control of tool geometry and process.
III. Recommendations for Berlt CBN Tool Machining Solutions
· Select the correct insert grade. For continuous turning conditions, choose high-wear-resistance PCBN inserts; for raceways or oil groove areas with interrupted cutting, select high-toughness composite CBN grades to improve chipping resistance.
· Reasonably control cutting parameters. Adopt the strategy of "high speed, shallow depth of cut, moderate feed": Vc: 110–150 m/min, F: 0.15–0.25 mm/rev, ap: 0.3–0.5 mm.
(Specific parameters should be optimized based on material and machine tool rigidity.)
· Cooling method. Prefer dry cutting to avoid thermal shock and dimensional drift caused by cutting fluid, which can further extend tool life.
IV. Case : Application of Berlt PCBN in Wind Turbine Bearing Machining
Workpiece: Slewing bearing, Material: 42CrMo, Hardness: HRC58-62;
Problem: Original tools had rapid wear, high scrap rate, and low efficiency;
Solution: Adopted Berlt BTS6500 grade PCBN tool RCGX0907, optimized turning parameters;
Result: Machining efficiency increased by 100%, workpiece surface roughness was good.
Zhengzhou Berlt, focusing on PCBN tool machining solutions, provides professional PCBN tool support for machining high-hardness materials such as bearings and automotive components. Welcome to leave a message to discuss your machining challenges, and help accelerate Chinese manufacturing!
