PCD & PCBN Tipped Boring Bars

High-Performance PCD & PCBN Tipped Boring Bars

Achieve superior precision and productivity in internal machining operations with ZYsuperhard’s PCD (Polycrystalline Diamond) and PCBN (Polycrystalline Cubic Boron Nitride) tipped boring bars. Specifically designed for demanding boring applications, these tools leverage the unique properties of PCD and PCBN to overcome the challenges of machining difficult materials, delivering exceptional accuracy, surface finish, and tool life directly within the bore. Choose PCD tips for boring non-ferrous metals and abrasive composites, or PCBN tips for efficient, high-quality boring of hardened steels, cast irons, and other hard ferrous materials.

The PCD Advantage in Boring Operations (Non-Ferrous & Abrasives)

Boring materials like aluminum alloys (especially high-silicon), copper, brass, and composites presents unique wear challenges. PCD tipped boring bars offer distinct advantages:

• Sustained Bore Accuracy & Finish: PCD’s extreme wear resistance means the cutting edge geometry holds its tolerance significantly longer than carbide. This translates directly to consistent bore diameters and superior surface finishes throughout the tool’s life, reducing rejects and secondary operations.
• High-Speed Internal Machining: The low friction and thermal stability of PCD allow for much higher cutting speeds (Vc) during the boring cycle, significantly reducing machining time per hole.
• Elimination of Built-Up Edge (BUE): PCD’s inertness prevents material adhesion (common with aluminum), ensuring a clean cut and preventing inaccuracies or damage to the bore surface finish.
• Ideal for Abrasive Materials: Effectively bore abrasive composites (CFRP, GFRP) or high-silicon aluminum where carbide wears rapidly, maintaining bore quality and extending tool life dramatically.

The PCBN Advantage in Boring Operations (Hard Ferrous Materials > 45 HRC)

Boring hardened steels, cast irons, or sintered metals requires a tool that can withstand high forces and temperatures within the confined space of a bore. PCBN tipped boring bars excel here:

• Efficient Hard Boring: PCBN retains its hardness at high temperatures generated during internal cutting, allowing for significantly faster cutting speeds and material removal rates compared to grinding or using carbide at slow speeds.
• Exceptional Bore Consistency: Outstanding wear resistance ensures the boring bar maintains the required diameter and profile accuracy over many components, critical for high-volume production or tight tolerance work.
• Handling Interrupted Cuts: Specific PCBN grades offer high toughness, making these boring bars suitable for applications with interrupted cuts within the bore (e.g., keyways, cross-holes) where standard tools might chip.
• Improved Hole Quality: The stable cutting action and wear resistance often lead to better roundness, straightness, and surface integrity within the bored hole.

Features of ZYsuperhard’s Boring Bars

• Optimized Tip Material Selection: Choose between PCD and PCBN tips based on the specific material being bored to maximize performance.
• Precision Ground Cutting Edges: Tips are ground to tight tolerances, ensuring accurate bore sizes, profiles, and smooth surface generation. The secure tip seat maintains positional accuracy.
• Robust Tip Brazing: High-strength brazing ensures the PCD or PCBN tip remains securely attached to the shank even under heavy or interrupted boring conditions, guaranteeing tool reliability.
• Shank Material Options for Boring Stability:
  • Steel Shanks: Provide a reliable and economical choice for general boring tasks.
  • Solid Carbide Shanks: Strongly recommended for small diameter boring bars, applications with long overhangs (high L/D ratios), or when maximum rigidity is needed to minimize deflection, dampen vibration, and achieve the highest bore tolerances and finishes.
• Application-Specific PCD/PCBN Grades: Select from various grades optimized for different workpiece materials and conditions (e.g., continuous vs. interrupted boring cuts, focus on finish vs. toughness).
• Internal Coolant Capability: Optional through-tool coolant channels deliver coolant directly to the cutting edge within the bore, significantly improving chip evacuation, reducing heat, and extending tool life, especially in deep hole boring.

Applications & Material Suitability for Boring

PCD Tipped Boring Bars are ideal for boring:

• Aluminum Alloys (all types), Copper, Brass, Bronze, Magnesium Alloys
• Composites (CFRP, GFRP, MMC), Graphite, Plastics, Green Ceramics

PCBN Tipped Boring Bars excel at boring:

• Hardened Steels (45-65+ HRC)
• Cast Irons (Grey, Ductile, CGI), Sintered Metals (PM)
• Hard Facing Alloys, certain Superalloys

Cutting Parameter Guidance for Boring

Achieving optimal results requires careful parameter selection tailored to the boring operation:

• Cutting Speed (Vc): Leverage the high-speed capabilities of PCD and PCBN, adjusting based on material, grade, bore diameter, and machine rigidity.
• Feed Rate (f): Balance productivity with desired surface finish (lower feeds for finer finishes). Consider chip formation and evacuation within the bore.
• Depth of Cut (Ap): Dependent on the rigidity of the boring bar (diameter, overhang), machine power, and material. Multiple passes may be needed for large diameter changes or deep bores.

Important Note: Optimal parameters depend heavily on the specific grade, workpiece details, machine setup (especially rigidity and damping related to the boring bar holder and overhang), coolant application, and required bore quality. Use recommended starting values and optimize through testing.

Tool Holding

Secure clamping in a high-quality, rigid boring bar holder or sleeve is paramount. Minimize tool overhang whenever feasible to maximize stability, prevent chatter, and ensure the best possible bore accuracy and finish.

Customization for Your Boring Needs

ZYsuperhard offers extensive customization options to create the ideal boring bar for your specific application challenges:

• Specific Shank Diameters and Lengths (including non-standard sizes)
• Custom Tip Geometries (e.g., specific radii, angles, profiling shapes for bore features)
• Optimized PCD/PCBN Grade Selection for your material/process
• Specific Edge Preparations
• Integrated Internal Coolant Configurations

Provide details of your boring application (material, hardness, bore dimensions & tolerances, machine type, etc.), and we will help configure or design the optimal PCD or PCBN tipped boring bar solution.