Planar milling applications are extremely common in the modern automotive industry. To meet the needs of the automotive industry, tool manufacturers have introduced milling cutters and inserts for milling cast iron and silicon-aluminum alloys. This tool and insert increase the processing efficiency and surface quality of the part. The cylinder block is one of the closed parts of the engine. The material is cast iron and silicon-aluminum alloy. The processing properties of different materials are different. For example, when processing gray cast iron, ductile iron and high-density ductile iron, these cast irons are all There are different processing characteristics, in which gray cast iron contains a network of hard structures, which is brittle. When machining, the tool is prone to chipping; ductile iron and high-density ductile iron have certain plasticity, which can produce iron filings, but when the tool is cut, The workpiece will also have a flange, which will result in damage to the tip. The same workpiece casting process is different, and the processing performance is also different. For different materials and different processing conditions, tool manufacturers have introduced a series of special blades, which play an extremely important role in the processing of automotive engines. Part name: engine cylinder head; Processing equipment: vertical machining center, wet processing; Cutting parameters: V c =200m/min, f=0.5mm/r, a p =2mm Each tool manufacturer has its own advantages in hole machining accuracy and machining efficiency. In order to meet the needs of the automotive industry, they have conducted in-depth research on tool materials, tool design and coating, especially in machining. When non-ferrous metals such as aluminum alloys have been developed, diamond-coated carbide drills, DLC coated carbide drills or drill bits with diamond sintered bodies have been developed, which greatly improves the service life of the tool and the workpiece. Dimensional accuracy. Material to be cut: 42CrMo, hardness HB250~300 Cutting speed: V c =75m/min, feed per revolution: f r =0.25mm/r, (speed n=1990r/min, feed rate V f =497.5mm/min) Drill life: 2988 drill holes, total cutting depth 89.4m 3 Application of CNC Forming Compound Tool in Cylinder Block Processing Previous page
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success case: Client unit: an automobile engine manufacturer;
Application of Solid Carbide Composite Tool in Automobile Manufacturing
Cutting case Drill specifications: Ø12
In short, the general trend of the cutting conditions of the drill bit is high speed, and the cutting speed can reach 200-300 m/min respectively depending on the material to be processed. High-speed drill cutting is a trend of high-speed and large-feeding, similar to the development trend of ball-end end mill cutting conditions. Cutting practice shows that increasing the cutting speed is beneficial to the rationalization of the chip shape and the improvement of the roughness of the machined surface. It is expected to develop along the direction of high-speed cutting in the future; increasing the feed rate is very beneficial for chip breaking and tool life extension. Therefore, in the future, it will continue to develop along the direction of the big feed.
As the competition in the automotive market continues to intensify and the profit margins become smaller and smaller, automakers continue to improve the automotive manufacturing process in order to reduce costs and improve processing efficiency. The content that previously required several processing steps to be completed is now combined. It is processed in one time, which not only shortens the processing time, improves the processing efficiency, but also further improves the machining accuracy of the parts and greatly reduces the processing cost. At this time, various forms of forming tools and compound tools are used. The most important role is that the blades of these forming tools can be welded or blade-shaped, and their structural forms are different according to different customer needs. In order to meet the constant demands of the automotive industry, Shanghai Tool Works Co., Ltd. developed various forms of composite forming tools in 2006. These tools combine PCD superhard tools with carbide tools to achieve rough machining. To the finishing of one molding, the current tools have been widely used in major automobile companies.
4 Application of CNC integral tool in crankshaft machining
Due to the particularity of the engine crankshaft structure, the current domestic car crankshaft production line is mostly a high-speed flexible production line FTL (Flexible Trallsfer Line). This production line is characterized by not only processing the same series of crankshafts, but also processing variant products, replacement products and new ones. product. CNC internal milling or CNC high-speed external milling should be preferred for crankshaft journal machining. CNC high-speed external milling is used for the processing of the connecting rod neck. If the blank is a forged steel blank, CNC internal milling is more conducive to chip breaking. It is not advisable to use the CNC car-car pull. Since the side of the balance block is intermittently turned, the crankshaft speed is very high (about 1000r/min), and the phenomenon of chipping is very serious. According to the characteristics of our company's products, we have great advantages in the processing of threaded holes on the crankshaft end face, the processing of straight oil holes and the processing of inclined oil holes. At present, our company's overall tools are already in Shanghai Volkswagen, SAIC Motor and General Motors. The company has been widely used.
5 Summary
This paper introduces the technical level of CNC tooling of Shanghai Tool Factory Co., Ltd. in the automotive processing industry by introducing the application of CNC tool in the automotive processing industry. In order to meet the increasingly high requirements of automotive processing, we are improving the development capability of CNC tool technology. It is also necessary to increase research on automotive processing technology and improve the quality of our technical services.
Application of face milling cutter on automobile cylinder block