1. Roll processing industry
Superhard tools have become a game changer for many large domestic roll companies. With these tools in hand, rough turning, rough turning, and finishing turning of various roll types, including chilled cast iron and hardened steel, can be done with ease and efficiency. These tools have enabled companies to achieve significant benefits and cost savings, such as increasing processing efficiency by up to 6 times and cutting processing time and electricity usage by 50% to 80%.
For instance, in the rough turning and semi-finishing of chilled cast iron rolls with a hardness of HS60-80, the cutting speed is increased by 3 times, translating to over 400 yuan in electricity and labor cost savings per roll car and nearly 100 yuan in tool costs. In another example, our school has used the FD22 cermet tool to turn 86CrMoV7 hardened steel rolls of HRC58~63, where the continuous cutting roll path reaches 15000m and meets the requirement of grinding instead of turning.
Overall, superhard tools are proving to be a cost-effective solution for various roll machining needs, enhancing productivity, and delivering significant economic benefits.
2. Industrial pump processing industry
Currently, the majority of domestic manufacturers of ballast pumps, about 70% to 80%, have adopted superhard tools. These ballast slurry pumps are widely used in various industries such as mining and electric power, and they have become in-demand products both domestically and internationally. In the past, machining this material was challenging and required a multi-step process involving annealing, softening, roughing, and quenching. However, with the introduction of super-hard cutting tools, the first-ever successful utilization of a hard tool has been achieved. This has greatly improved the efficiency and effectiveness of ballast pump manufacturing. Apart from the mining and electric power sectors, the automobile processing industry has also benefited from these advancements.
In the automotive and agriculture industries, the processing of hardened workpieces such as crankshafts, camshafts, transmission shafts, cutting tools, and measuring tools can often pose a challenge. For instance, a locomotive and rolling stock factory recently encountered a problem when trying to process the inner ring of a bearing during equipment maintenance. The inner ring was made of GCr15 steel with a hardness of HRC60, and had a diameter of f285mm. Initially, the grinding process was attempted, but the grinding allowance was uneven, and it took upwards of 2 hours to achieve a satisfactory result. However, once a super-hard tool was introduced, the processing time for an inner ring was reduced to just 45 minutes. Such improvements in processing can have a significant impact on reducing downtime and enhancing productivity in these crucial industries.