Iwaki, Japan – September, 2025 – Tungaloy Corporation (President: Satoshi Kinoshita, Head Office: Iwaki City, Fukushima Prefecture) announces the expansion of its CBN insert lineup with the launch of new grade “BX4015,” designed for high-efficiency machining of sintered alloys, offering exceptional wear resistance and tool life stability across a wide range of ISO insert shapes.
Challenges and Trends
In the mass production of powder metallurgy (PM) components for automotive powertrain and electrification applications, chipping and breakage due to interrupted cutting are frequently encountered. These issues lead to variations in tool life and a decline in surface quality. Moreover, differences in the characteristics of sintered materials from batch to batch make it difficult to optimize cutting conditions, which negatively impacts production efficiency and cost. In the field, there is a strong demand for low-resistance cutting achieved by sharp cutting edges, while also maintaining toughness and wear resistance to prevent edge chipping. It is crucial to ensure high tool life and stable machining performance while maximizing cost performance.
Product Overview
BX4015 is a CBN grade designed for machining sintered alloys. It is suitable for finishing to light cutting, providing stable burr suppression and surface quality. The grade is easy to use in continuous and interrupted machining of outer diameters and end faces, and it also supports sharp-edge applications. With a wide variety of insert geometries, BX4015 contributes to stable mass production.
Benefits and Features
Feature 1: High Wear Resistance with High-Content CBN Grade
- Suppresses wear progression with a high-hardness binder.
- Enables extended tool life even during long continuous operations or when cutting high-hardness materials.
- Delivers stable machining performance even on challenging materials such as sintered alloys.
Feature 2: High Fracture Resistance with Special Binder Material
-
- Adopts a special binder that enhances the interfacial strength between CBN particles and the binder.
- Suppresses sudden chipping or breakage, increasing machining reliability.
- Maintains stable cutting performance under high-load conditions, reducing the risk of trouble.
Feature 3: Improved Edge Strength and Surface Finish with Fine CBN Particles
-
-
- The use of fine CBN particles results in a sharper and more stable cutting edge.
- Reduces the occurrence of burrs and chipping, improving the quality of the machined surface.
- Achieves smooth and high-precision cutting, even in finishing applications.
-
Cutting Performance
| Insert | CNGA120408F |
| Cutting speed | Vc = 300 m/min |
| Feed | f = 0.1 mm/rev |
| Depth of cut | ap = 0.2 mm |
| Machining | Interrupted face turning |
| Coolant | Wet |
BX4015 has demonstrated consistent fracture resistance.
Success Stories
IMPROVED TOOL LIFE
BX4015 demonstrated excellent chipping resistance, provided good surface quality, and achieved 1.5 times tool life increase.
| Industry | Automotive |
| Component | Sprocket |
| Material ISO code |  H – Hardened material |
| Work material | Iron-based sintered alloy |
| Machine(spindle type) | CNC Lathe |
| Tool family | Turning |
| Tool category | Internal boring |
| Product name | BX4015 |
| TSR No. | 5355T |
IMPROVED TOOL LIFE
Boasting excellent edge-line security, BX4015 successfully eliminated burr formation on interrupted parts, while extending tool life by 1.6 times.
| Industry | Automotive |
| Component | Sprocket |
| Material ISO code | H – Hardened material |
| Work material | Iron-based sintered alloy |
| Machine(spindle type) | CNC Lathe |
| Tool family | Turning |
| Tool category | Internal & Face turning |
| Product name | BX4015 |
| TSR No. | 5356T |
