High-Efficiency Machining Solutions for Cast Iron Flanges

Flanges, as core components of mechanical connection systems, are widely used in mining machinery, compressors, automotive parts, and other fields. Machining cast iron flanges often faces challenges such as easy chip accumulation, tool wear caused by high-hardness impurities, and significant differences in cutting performance among different grades of cast iron.  This is especially true for the demanding requirements of impact resistance in rough machining and precision stability in finish machining.

SCBN TOOLS possesses comprehensive performance advantages far exceeding traditional cemented carbide and ceramic tools. CBN inserts have high hardness, excellent wear resistance and heat resistance, and a long service life. They are suitable for the dry cutting conditions commonly used in cast iron machining and do not react with ferrous materials at high temperatures, effectively solving the problem of chip adhesion in cast iron machining. Leveraging its deep technical expertise in the field of superhard cutting tools, SCBN TOOLS provides high-precision, high-efficiency, and low-cost solutions for cast iron flange machining.

SCBN TOOLS Inserts Compatibility:

1.WNGA inserts feature a triangular cutting edge structure, offering excellent chip evacuation, high bending strength, and fracture toughness. They can withstand the impact force of heavy-duty cutting and are suitable for rough machining of gray cast iron flanges. They can handle strong intermittent cutting of cast iron containing impurities and are also compatible with machining small-diameter inner bore cast iron flanges, offering exceptional versatility.

2.SNGA inserts have a square structure with excellent cutting edge strength. Optimized with a nano-coating, they are suitable for semi-finishing of ductile iron flanges. Their sharp cutting edges reduce cutting force and prevent chipping of the cast iron material, making them suitable for continuous and weakly intermittent cutting conditions on outer diameters and end faces.

3.DNGA inserts feature a rhombic cutting edge design with a wide range of selectable tip radius options, combining sharpness and stability. They are suitable for precision machining of cast iron flange sealing surfaces, effectively suppressing chatter marks. With appropriate parameters, the surface roughness can be controlled within a high-quality range, meeting the requirements of sealing applications.

Typical Applications:

1.For rough machining of gray cast iron flanges, WNGA  inserts are used.  With a cutting speed of 150-180 m/min, feed rate of 0.15-0.25 mm/rev, and depth of cut ≤2 mm, the single-edge tool life is 3-5 times longer than traditional carbide tools.  Excellent chip evacuation prevents chip accumulation and workpiece scratching. This is suitable for mass production of gray cast iron flanges in mining machinery and compressors.

2.For finish machining of cast iron flange sealing surfaces, DNGA inserts are used, enabling "turning instead of grinding." The surface roughness is stably controlled within Ra1.6 μm, eliminating subsequent grinding processes and significantly improving processing efficiency.