High-Performance Machining of Hard Rolls Using PCD and CBN Tools

In modern steel production, rolls are one of the most critical components in rolling mills. As essential tools for shaping ferrous metals, the quality and durability of rolls directly impact productivity, surface finish, and overall cost efficiency in metallurgical operations. In fact, roll-related costs can account for 5% to 15% of the total production expenditure in steel plants.

Rolls used in hot and cold rolling applications include a wide range of types, such as:

• Cast rolls.
• Forged rolls.
• Tungsten carbide (WC/TC) composite rolls.

These rolls are typically extremely hard, large in size, and often come with casting defects such as shrinkage cavities, porosity, and hard spots. This makes their machining highly challenging and places stringent demands on cutting tools.

Optimized Solution: CBN and PCD Cutting Tools

At CYKC GROUP, we provide precision solutions for high-hardness roll machining using advanced PCD (Polycrystalline Diamond) and CBN (Cubic Boron Nitride) tool technology. These superhard tools outperform traditional carbide tools by offering:

• Higher wear resistance.
• Greater thermal stability.
• Improved productivity.
• Reduced tool change frequency and production costs.

CBN Inserts for Rough Machining of Hard Rolls

For rolls with hardness levels up to HRA88, especially tungsten carbide (WC) rolls and cast steel rolls, our solid CBN inserts are highly recommended for heavy-duty rough turning. These inserts are specifically engineered to:

• Withstand the impact of sand inclusions, porosity, and uneven hardness zones.
• Deliver stable performance under continuous or interrupted cutting.
• Achieve deep cuts and high feed rates even under harsh conditions.

Application example:

Rough turning of HSS or chilled cast iron rolls using CBN inserts can increase cutting speeds by over 200% compared to carbide, while also extending tool life significantly.

PCD Tools for Finish Machining and Engraving

PCD tools are best suited for finishing operations on roll surfaces, such as:

• Cylindrical turning.
• Chamfering.
• Surface finishing.
• Engraving roll identification codes or logos.

For applications demanding excellent surface finish and tight tolerances, PCD performs exceptionally well. It is particularly effective when machining non-ferrous overlays or composite roll materials.

CYKC’s Superhard Tooling Advantages

With years of accumulated expertise, CYKC GROUP has become a trusted name in the superhard tooling industry. Our continuous innovation in materials science and tooling technology has led to the development of tailored CBN and PCD tool solutions for hard roll machining.

Key Benefits:

• Custom geometry designs for specific roll profiles.
• Enhanced chip control and thermal resistance.
• Competitive pricing and consistent performance.
• Technical support and on-site optimization service.

Applications in Metallurgical Industry

Want More Info?

We provide complete roll machining solutions, including tool selection, cutting parameter optimization, and failure analysis. Contact us for:

• Technical brochures.
• Free cutting trial reports.
• Custom tool design inquiries.

CYKC GROUP — Your Trusted Partner in Superhard Cutting Technology.

E-mail: cykc@cykcgroup.com.cn