In optimizing the overall performance of PCBN tools, the rational selection of edge preparation styles directly affects their service life and cutting efficiency. The actual choice requires systematic analysis based on various factors such as the physical characteristics of the workpiece material, cutting parameter configuration, specific working condition requirements, and tool substrate material. Below, based on years of technical practice by Berlt Superhard, a set of practical and reliable edge selection recommendations is compiled for industry reference.

1、Selecting Edge Preparation Based on Workpiece Material Characteristics

·High-hardness materials: It is recommended to use an edge design with a larger negative rake angle and wider width. For example, when machining quenched steel with Berlt BT6000 inserts, model S02030 adopts a 30º negative rake angle and 0.2mm width, which effectively enhances the tool’s structural strength and reduces the risk of chipping.

·High-toughness materials: It is suitable to choose an edge with a smaller negative rake angle and narrower width. For instance, when machining cast iron with Berlt BT2800 inserts, model T01015’s 15º negative rake angle and 0.1mm width help improve cutting efficiency and surface quality of the finished product.

2、Adjusting Edge Preparation According to Cutting Parameters

·High-speed cutting: An edge with a small negative rake angle and narrow width should be selected, along with appropriate honing, to reduce cutting resistance and friction heat, thereby improving efficiency. Edge honing can also mitigate cutting impact and vibration.

·Low-speed heavy cutting: An edge with a large negative rake angle and wide width is required to enhance the tool’s ability to withstand high cutting forces and impact. In this case, honing can be increased, as cutting forces and vibrations are relatively lower at low speeds.

3、Determining Edge Style Based on Machining Conditions and Cutting Environment

·Continuous cutting: For continuous operations requiring high precision and good surface quality, an edge with a small negative rake angle and appropriate honing is advisable to reduce vibration and heat accumulation, thereby improving machining accuracy.

·Intermittent cutting: For intermittent cutting requiring high durability and impact resistance, an edge with a large negative rake angle and reinforced honing should be selected to enhance the tool’s damage resistance and service life.

4、Considering Tool Material Factors

·Tool material: Different PCBN grades possess unique mechanical properties and cutting performances. Edge preparation must be matched accordingly when making selections.

In summary, optimizing the selection of PCBN tool edge preparation styles requires detailed analysis of multiple factors, including workpiece material, cutting parameters, machining environment, and the tool’s own characteristics. As a pioneer in high-speed heavy cutting in China, Berlt Superhard significantly enhances tool performance and machining efficiency through precise matching of insert grades and material combinations, injecting strong momentum into modern manufacturing.