Full-Edge Brazed CBN Inserts (Full-Face PCBN Cutting Tools)
UKing Diamond’s factory-direct full-edge brazed CBN inserts provide continuous cutting edges for large depth-of-cut (ap) operations, delivering exceptional wear resistance, superior surface finishes, and extended tool life in high-feed hard turning and finish machining of hardened steel (HRC55–65).
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Description
Uking Diamond’s Full-Edge Brazed CBN Inserts are designed for high-feed, continuous, and lightly interrupted finish-machining lines. By replacing standard localized tiny tips with a continuous full-edge PCBN structure, these inserts eliminate the step-marks and thermal stress concentrations associated with segmented cutting boundaries:
High-Efficiency Automotive Transmission Gears & Shafts
Supports deep axial turning passes on long hardened shafts (HRC 56–62), ensuring zero dimensional taper and absolute geometric cylindricity from end to end.
Large Industrial Hydraulic Cylinders & Plungers
Handles extended, continuous skiving and hard-turning operations over large surface areas without requiring mid-pass insert indexing.
Bearing Inner & Outer Rings Face Turning
Eliminates localized edge chipping during wide-face plunging and continuous race tracking, stabilizing sub-micron flatness.
Precision Die & Mold Core Finish Profiling
Maximizes continuous high-speed cutting path length in hardened tool steels (HRC 60+), achieving mirror-like finishes ( ≤0.4) directly from the lathe.
Models & Specs
| ISO Standard Model | Insert Shape & Topography | Primary Mechanical Application | Industry Standard Sizes |
| CNGA Series | 80° Rhombic (Continuous full-edge) | [Long-Edge Continuous Hard Turning] Maximum cutting edge length for deep axial profiling and finishing of long transmission gears. Exceptional dimensional tracking. | CNGA 120404, CNGA 120408, CNGA 120412 |
| DNGA Series | 55° Rhombic (Profile flexibility) | [Seamless Contour Copying & Profiling] Narrow clearance combined with a whole-edge layer for smooth, uninterrupted copying passes in mold cavities. | DNGA 150404, DNGA 150408, DNGA 150608 |
| TNGA Series | 60° Triangle (Extended edge economics) | [High-Depth Facing & Shouldering] Unlocks three continuous full-length cutting margins per insert, optimizing tooling economy during high-feed vertical shoulder clearing. | TNGA 160404, TNGA 160408, TNGA 160412 |
| WNGA Series | 80° Trigon (Robust multi-edge) | [Medium Finishing & Light Interruption] High bulk toughness configuration providing wide-angle clearance for face turning and outer diameter skin passes. | WNGA 080404, WNGA 080408 |
| VNGA Series | 35° Rhombic (Intricate clearance) | [Ultra-Narrow Recess V-Grooving] Full-length welded edge for deep, intricate grooving and back-profiling where standard small tips would cause holder interference. | VNGA 160404, VNGA 160408 |
1. Continuous Seamless Cutting Edge vs. Fragmented Small Tips
Standard tipped CBN inserts only have a microscopic patch brazed at the very corner. If your depth of cut ($a_p$) exceeds 0.5 mm or if you are running an axial profiling path with a variable depth, the cutting action forces the chips across the brazing boundary line. This causes rapid thermal erosion, seam melting, and severe edge splitting.
Uking’s Full-Edge Brazed CBN Inserts feature a continuous, complete length of industrial-grade PCBN along the entire edge profile. Sintered and laser-welded with high-density vacuum diffusion techniques, there are zero internal seams along the active cutting length. This permits you to significantly increase your single-pass axial depth of cut (ap), transforming slow, multi-pass cycles into a single, high-efficiency finish pass.
2. Superior Rigidity of Carbide Substrate with PCBN Efficiency
Unlike Solid CBN inserts which can sometimes suffer from structural brittleness on small, intricate tool bodies, Whole Welding inserts utilize the high impact dampening properties of a dense tungsten carbide backing.
The carbide base absorbs spindle micro-vibrations and high bending moments during deep cuts. Meanwhile, the continuous whole-welded PCBN edge handles the immense friction temperatures (≥ 900°C) of hard turning (HT). This optimal hybrid structure delivers unparalleled surface finish consistency (Ra≤0.4 μm) over high-volume automated production shifts.
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Why Choose Uking Diamond Whole Welding?
– Continuous Full-Length Welded Edge: Permits deep single-pass profiling without encountering localized brazing seam failures.
– Zero Boundary Step-Marks: Guarantees absolute surface perfection and pristine smoothness, eliminating microscopic ridges on long workpiece shafts.
– Dampened Carbide Spine Core: Combines diamond-grade hardness with the vibration-absorbing elasticity of a heavy carbide body to prevent chatter.
– High Micron-Level In-Line Accuracy: Strict laser-sharpened profile tolerances fit perfectly into global standard negative tool holders with zero centerline play.
Application
Parameters
Model: CNGA1204-ZH
Cutting Edge Length(mm): 12.9
Inscribed Circle(mm) : 12.7
Thickness(mm): 4.76
Grade: UKS6000 UKS6000A UKS2800 UKS7800
Remark: Nose Radius
Model: TNGA1604-ZH
Cutting Edge Length(mm): 16.5
Inscribed Circle(mm) : 9.525
Thickness(mm): 4.76
Grade: UKS6000 UKS6000A UKS2800 UKS7800
Remark: Nose Radius
Model: WNGA0804-ZH
Cutting Edge Length(mm): 8.7
Inscribed Circle(mm) : 12.7
Thickness(mm): 4.76
Grade: UKS6000 UKS6000A UKS2800 UKS7800
Remark: Nose Radius
Model: VNGA1604-ZH
Cutting Edge Length(mm): 16.6
Inscribed Circle(mm) : 9.525
Thickness(mm): 4.76
Grade: UKS6000 UKS6000A UKS2800 UKS7800
Remark: Nose Radius
Model: DNGA1504-ZH
Cutting Edge Length(mm): 15.5
Inscribed Circle(mm) : 12.7
Thickness(mm): 4.76
Grade: UKS6000 UKS6000A UKS2800 UKS7800
Remark: Nose Radius
Model: DNGA1506-ZH
Cutting Edge Length(mm): 15.5
Inscribed Circle(mm) : 12.7
Thickness(mm): 6.35
Grade: UKS6000 UKS6000A UKS2800 UKS7800
Remark: Nose Radius
Are your automated precision hard turning lines constantly leaving microscopic step-marks, or are your brazed CBN corners failing prematurely whenever you increase your depth of cut (ap) on long hardened shafts?
Stop limiting your cycle times with cheap, single-tipped inserts that restrict your machining depth and melt under prolonged thermal loads. Backed by 20 years of vacuum-diffusion and advanced automated laser-welding synthesis engineering authority in Henan, China, Uking Diamond supplies high-output manufacturing plants with industrial-grade Whole Welding Full-Edge CBN inserts that keep your finishes perfect and your production lines profitable.
Because full-edge welded PCBN inserts are precision-engineered, high-performance production assets rather than generic commodity shop items, we align exclusively with high-intent industrial evaluations rather than distributing unmonitored free samples.
Ready to double your depth of cut and achieve seamless finish surfaces? Contact our global tool engineering division today with your current ISO configuration (e.g., CNGA 120408), your exact workpiece dimensions/hardness (HRC), and your current machining cycle limitation (e.g., seam cracking or multi-pass slowdowns). Our team will instantly activate your Corporate Whole-Welding Evaluation Pass: obtain a prioritized test batch of our advanced full-edge welded inserts at direct factory-wholesale pricing, with 100% of the sample evaluation fee fully credited back to your account upon your first bulk commercial order.
[ Contact Our Global Tooling Desk & Request Your Whole Welding CBN Quote Now ]
FAQ
Q1: What are Full-Edge Brazed CBN inserts, and what machining advantages do they provide?
A: UKing Diamond’s Full-Edge Brazed CBN inserts feature a continuous PCBN cutting edge brazed along the entire active cutting zone of a carbide substrate. Unlike conventional brazed CBN inserts that utilize a localized PCBN tip at each corner, the full-edge design provides uninterrupted cutting engagement across the complete edge length.
This construction enables several machining advantages:
- Deep hard turning with depths of cut up to 1.5 mm
- Continuous profile machining without edge transition marks
- Improved edge stability during long-pass finishing operations
- Hard turning as an alternative to certain cylindrical grinding processes
As a result, UKing Diamond’s Full-Edge Brazed CBN inserts are widely used for transmission shafts, bearing races, hydraulic components, mold cores, and other hardened steel parts requiring excellent dimensional consistency and surface quality.
Q2: What workpiece hardness range is best suited for Full-Edge Brazed CBN inserts?
A: UKing Diamond’s Full-Edge Brazed CBN inserts are primarily designed for machining hardened steel in the HRC 45–65 range, with optimal performance typically achieved between HRC 55–62.
Within this hardness range, the inserts provide an excellent balance of wear resistance, edge strength, and surface finish quality during hard turning operations.
For materials below HRC 45, carbide tooling is often the more economical choice. For extremely hard materials above HRC 65, solid CBN inserts may provide greater edge integrity under severe cutting conditions.
For high-volume cast iron roughing applications where tooling economy is the primary objective, UKing Diamond’s indexable CBN inserts are generally the preferred solution due to their multiple usable cutting edges.
Q3: Can Full-Edge Brazed CBN inserts replace cylindrical grinding in hardened steel finishing?
A: In many applications, yes. UKing Diamond’s Full-Edge Brazed CBN inserts are capable of achieving surface finishes of approximately Ra 0.2–0.4 μm on hardened steel components while maintaining excellent dimensional accuracy.
Compared with conventional cylindrical grinding, hard turning offers several advantages:
- Reduced cycle times
- Single-setup machining
- Elimination of grinding wheel dressing
- Lower equipment investment
- Greater flexibility for machining shoulders, grooves, and multiple diameters in one clamping
Typical applications include automotive transmission shafts, bearing components, hydraulic rods, and precision mechanical parts.
However, grinding remains the preferred process when ultra-fine surface finishes below Ra 0.1 μm, extremely tight roundness requirements, or ultra-precision tolerances are required.
