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PCBN tool market prospect analysis
Abstract The development and application of high-speed cutting technology are heavily influenced by advancements in both machine tools and tooling technologies, with the progress of tool materials playing a critical role. Research has shown that during high-speed cutting, as the cutting speed increases, the cutting force tends to decrease, while the cutting temperature rises significantly. Once it reaches a certain threshold, the temperature increase gradually slows down.
The primary causes of tool failure under these conditions include mechanical wear and breakage due to friction, adhesion, chemical erosion, chipping, crushing, and plastic deformation caused by the combined effects of cutting forces and high temperatures. Therefore, for high-speed cutting, the most essential requirements for tool materials include excellent mechanical properties at elevated temperatures, favorable thermophysical characteristics, anti-sticking behavior, chemical stability (such as resistance to oxidation, diffusion, and solubility), and good thermal shock and coating crack resistance.
Based on these demands, PCBN (Polycrystalline Cubic Boron Nitride) tool materials are well-suited for high-speed cutting applications across various workpiece materials and cutting conditions. Currently, they can cut steel at speeds ranging from 2000 to 5000 m/min, and also handle hardened steel at 100–200 m/min. This versatility makes PCBN an ideal choice for modern machining processes.
Cemented carbide tools, which are widely used today, are primarily tungsten-cobalt based. China is one of the world’s largest producers of tungsten, supplying about 75%–80% of global demand. However, according to some studies, the global reserves of tungsten are expected to last only 50–70 years. The rapid development of PCBN tools presents a promising solution to this resource challenge. In the future, new tool materials will increasingly rely on cubic boron nitride, especially in the machining of ferrous metals, to support pollution-free, clean, and energy-efficient green cutting processes.
PCBN tools are known for their high hardness, excellent wear resistance, and strong chemical stability. They are ideal for green manufacturing techniques such as high-speed cutting, dry cutting, and hard turning, without the environmental impact associated with cutting fluids. With the rapid advancement of CNC machining technology and the widespread use of CNC machines, the production and application of super-hard tools like PCBN are expanding rapidly.
Currently, PCBN tools are extensively used in various industrial sectors, including automotive parts, bearings, and gear manufacturing. Their adoption has significantly advanced cutting technologies and modern manufacturing practices. Due to their superior fracture toughness, wear resistance, and chemical stability, PCBN tools have become the preferred choice for machining hardened steels and different types of cast iron.
Thanks to their exceptional performance in terms of machining accuracy, cutting efficiency, and tool life, the implementation of PCBN tools can greatly enhance productivity while reducing costs. Modern cutting processes—such as green machining, grinding, milling, hard turning, high-speed cutting, and dry cutting—are all made possible through the use of PCBN tools. As a result, PCBN tools have become an indispensable part of the machining industry. In the coming years, the market share of PCBN tools is expected to grow steadily, making them an irreversible trend in the field of advanced manufacturing.