In recent years, Great Wall Company's car engine factory has built three flexible machine and production lines with high-speed and high-efficiency machining centers of world-renowned machine tool manufacturers. Together with the world-renowned tool manufacturer Kenner, the company has carefully selected tools in combination with processed products. Achieve high speed and efficient cutting.
(1) KSCM-AluMill face milling cutter In the cylinder and cylinder head production line, we use Kennametal KSCM-AluMill face milling cutter for the face milling of aluminum alloy cylinder blocks and cylinder heads. The tool consists of a steel cutter head and an aluminum cutter body, which reduces the weight while ensuring sufficient rigidity, and the bimetal structure also reduces machining vibration. The tool features high metal removal, low processing burrs and high processing efficiency, making it ideal for high speed cutting. The KSCM-AluMill face milling cutter has five types of tool holders. Different tool holders are used for roughing and finishing milling to achieve different surface roughness. It is also possible to install rough and fine milling tool holders at the same time. Complete once, shorten processing time and improve work efficiency.
In the actual processing, we have selected KD1415 and KD1420 PCD cutting material holders for processing low-silicon aluminum alloy with high wear resistance and high life. KD1415 blade has high hardness and is suitable for processing uniform surface and uniform hardness surface. Therefore, it is used for finishing of cylinder block, cylinder head upper and lower and front and rear surfaces. KD1420 tool holder has good blade toughness and is suitable for the balance. Uniform, inconsistent hardness surfaces are used for roughing. After finishing, the flatness error of the large plane such as the cylinder block, the upper and lower faces of the cylinder head, the front and the back is not more than 0.02mm, the minimum is 0.0034mm, the average flatness error is not more than 0.01mm, and the surface roughness is lower than Ra0.8. The processing cycle meets the requirements. When the KSCM-AluMill face milling cutter replaces the tool holder, only the axial adjustment is made, no radial adjustment is needed, and the adjustment is convenient, the adjustment time is short, and the adjustment precision is high. When the Great Wall Company actually uses it, the axial adjustment deviation is not realized. More than 0.003mm, the cutting load is evenly distributed to each tooth, effectively extending the tool life. After several months of trial processing, the KSCM-AluMill face milling cutter has a good aluminum alloy processing effect.
For example, the top and bottom surface of the cylinder are finely milled. The top surface of the milling cutter Φ100, Z12 (9 fine milling cutter holders, 3 polishing tool holders), the light repair amount is 0.008+0.002mm, the overall welding PCD blade; processing parameters :V=2500m/min, fz=0.12mm/z, Vf=11.5m/min; the actual test piece after finishing milling, the surface roughness Ra0.8, the flatness error <0.004, the beat meets the requirements. Finishing cutter Φ200, Z24 (18 finishing cutters, 6 wiper clamps), machining parameters: V=2500m/min, fz=0.12mm /z, Vf=14.3m/min; Piece, surface roughness Ra0.8, flatness <0.004mm, the beat meets the requirements.
(2)Composite machining tool Composite machining is a very effective means to improve machining efficiency. Several machining contents are completed in one process with one knife, which reduces the number of tool changes, saves auxiliary time and improves production efficiency. Step drill is the simplest and most common type of compound machining tool. The drill with chamfering edge is the simplest step drill. In the processing of the cylinder block and the cylinder head hole, the simple step drill is selected for the drilling process in which the hole needs chamfering, and good results are obtained. For example, Kenner's straight groove 180° apex angle TX step drill bit has almost zero radial force when drilling, and four linear lands are symmetrically distributed along the circumference. It has good guiding properties and has a light-reducing effect to make the straightness of the drilling. And the degree of position has been greatly improved. In the machining of cylinder block and cylinder head hole, the other compound drill bit is a TF drill bit with three cutting edges on the circumference. The drill core is thicker and stronger than the two-blade drill bit, which makes up for the weakness of the hard alloy toughness. The special shape of the front end of the tool tip can be self-centering without machining the center hole; the cutting edge increases the feed per revolution (up to 20m/min when cutting aluminum), high strength, high-speed cutting (cutting aluminum) The maximum time is up to 1000m/min), which greatly shortens the processing time and improves the processing efficiency. It is especially suitable for deep hole machining. The dimensional accuracy is up to H9, the positional accuracy is up to ±11μm, and the roughness is Rz20~25.
In the Great Wall crankshaft production line, Kennametal solid carbide SE step drill is selected, which has higher drilling roundness than ordinary high speed steel drill. The drilling roundness of high speed steel drill can reach 20μm, and SE drill bit The roundness of the hole is only 1/5 of the former. According to the accuracy of this hole shape, we can completely consider the process of eliminating the reaming. In some cases, it can even replace the reaming that is not required (such as the threaded bottom hole of the extruded thread). The drill bit is characterized by a shorter cross-edge grinding and reduces the axial force by nearly 50%; the rake angle near the core is positive, so the cutting edge is sharper; the groove shape is parabolic, and the core thickness is larger. The drill bit has higher strength and stronger rigidity; there are two injection cooling holes, and the cooling condition is good; the arc-shaped cutting edge and the chip flute type are arranged reasonably, which is convenient for the chip to be broken into small pieces and smoothly discharged. The drill bit is used for drilling the front and rear ends of the crankshaft with good results.
(3) Precision hole processing tools The rapid development of modern industry puts higher requirements on the dimensional accuracy, geometry and surface roughness of the hole, especially in the automotive industry, which requires high precision and requires large quantities, thus requiring high efficiency. Precision hole machining tool. Diamond reamer is a precision tool developed to meet this need. In the cylinder head production line conduit and the seat bottom hole, the Kennametal blade integrated welding PCD reamer was used; the cylinder head cylinder positioning hole was finished, and the Kenner Bencere split type indexable PCD reamer was used. High-speed and high-efficiency cutting has been realized, and the performance of the high-speed machining center has been fully utilized, which has greatly improved the processing efficiency. The actual sampling of some products in the field? 8, 10 and 13 three sets of holes, the size range of variation within 0.014, the maximum dimensional accuracy error is less than 60% of the tolerance, the average error is less than 0.005mm, the surface roughness of the hole <Ra0. 8.
The cylinder crankshaft hole finishing and the cylinder head camshaft hole finishing use the Kennamese BencereQUATTRO-CUT tool, and the 4-blade indexable insert is mounted in a high-precision sawtooth pocket with dimensional accuracy controlled at μ level. Compared to conventional split indexable tools, the QUATTRO-CUT tool only needs to adjust the radial height of the insert, eliminating the need to adjust the blade back cone and reducing the adjustment time. According to the sampling record, the crankshaft hole is finely tuned. Dimensional accuracy machining error <0.018mm, coaxiality error <0.016mm, minimum error only 0.0021mm, roughness <Ra1.6; fine camshaft hole, coaxiality error <0.007, minimum error 0.0014mm, roundness The error is <0.002mm, the position error is <0.063, the minimum error is 0.0148mm, the dimensional accuracy deviation is <0.018mm, and the minimum deviation is 0.0044mm. The processing of the two sets of holes can meet the beat requirements, and the trial processing has produced hundreds of pieces so far, with good results.
(4) Cylinder bore and crankshaft machining tool The cylinder block of the cylinder line of the Great Wall Company, the cast iron cylinder liner of the cylinder bore, the rough machining of the cylinder bore is a large amount of cast iron processing, which requires high strength and toughness of the knife. Consider using the Kenner Fix-Perfect tool. The Fix-Perfect tooling system is a product line with different positive and negative angle combinations. It features a negative radial rake angle and a positive axial rake angle. The positive axial rake angle reduces the axial cutting force and The negative radial rake angle creates a good shearing effect for chip breaking. The positive axial rake angle causes the cutting force to be directed toward the main shaft, which makes the milling cutter work more stable. Moreover, the negative radial rake angle can make the earliest "impact point" that cuts into the workpiece away from the cutting edge and protect the cutting edge. The blade is vertically mounted, and the lower part of the blade has a strong physical support, which increases the strength of the blade. Fix-Perfect tool processing accuracy, surface roughness are good, the only drawback is that the life is too low.
In the crankshaft production line, the KM tool system is used for the machining of the main journal and the front and rear end journals. The KM tool system was jointly developed by Kennametal Corporation of the United States and WIDIA of Germany. Its basic shape is similar to that of HSK. It also adopts a 1:10 hollow short cone fit and double-sided positioning. The main difference is the difference of the clamping mechanism. The KM shank is locked by the inclined surface of the steel ball. When clamping, the steel ball is pushed out along the inclined surface of the groove of the rod, and is stuck on the inclined surface of the locking hole on the shank. The shank is tightened to the spindle hole, and the shank is elastically deformed so that the end surface of the shank is in close contact with the end surface of the spindle. KM tool systems offer the advantages of high stiffness, high precision, fast clamping and easy maintenance. Tests have confirmed that the KM shank has a higher dynamic stiffness than the HSK system.
Coated carbide inserts such as KC9315 are used in the turning of the crankshaft main journal and the front and rear journals. The CVD composite coating has a thick K-MTCVD alumina layer, which is excellent in wear resistance and thick. KMTCVDTiCN coating ensures long life and can be used for high speed continuous cutting or slight interrupted cutting, especially for processing grey cast iron or ductile cast iron. In the crankshaft machining, the cutting speed reaches 223m/min, and the cycle meets the requirements, achieving high-speed, high-efficiency machining.
(1) KSCM-AluMill face milling cutter In the cylinder and cylinder head production line, we use Kennametal KSCM-AluMill face milling cutter for the face milling of aluminum alloy cylinder blocks and cylinder heads. The tool consists of a steel cutter head and an aluminum cutter body, which reduces the weight while ensuring sufficient rigidity, and the bimetal structure also reduces machining vibration. The tool features high metal removal, low processing burrs and high processing efficiency, making it ideal for high speed cutting. The KSCM-AluMill face milling cutter has five types of tool holders. Different tool holders are used for roughing and finishing milling to achieve different surface roughness. It is also possible to install rough and fine milling tool holders at the same time. Complete once, shorten processing time and improve work efficiency.
In the actual processing, we have selected KD1415 and KD1420 PCD cutting material holders for processing low-silicon aluminum alloy with high wear resistance and high life. KD1415 blade has high hardness and is suitable for processing uniform surface and uniform hardness surface. Therefore, it is used for finishing of cylinder block, cylinder head upper and lower and front and rear surfaces. KD1420 tool holder has good blade toughness and is suitable for the balance. Uniform, inconsistent hardness surfaces are used for roughing. After finishing, the flatness error of the large plane such as the cylinder block, the upper and lower faces of the cylinder head, the front and the back is not more than 0.02mm, the minimum is 0.0034mm, the average flatness error is not more than 0.01mm, and the surface roughness is lower than Ra0.8. The processing cycle meets the requirements. When the KSCM-AluMill face milling cutter replaces the tool holder, only the axial adjustment is made, no radial adjustment is needed, and the adjustment is convenient, the adjustment time is short, and the adjustment precision is high. When the Great Wall Company actually uses it, the axial adjustment deviation is not realized. More than 0.003mm, the cutting load is evenly distributed to each tooth, effectively extending the tool life. After several months of trial processing, the KSCM-AluMill face milling cutter has a good aluminum alloy processing effect.
For example, the top and bottom surface of the cylinder are finely milled. The top surface of the milling cutter Φ100, Z12 (9 fine milling cutter holders, 3 polishing tool holders), the light repair amount is 0.008+0.002mm, the overall welding PCD blade; processing parameters :V=2500m/min, fz=0.12mm/z, Vf=11.5m/min; the actual test piece after finishing milling, the surface roughness Ra0.8, the flatness error <0.004, the beat meets the requirements. Finishing cutter Φ200, Z24 (18 finishing cutters, 6 wiper clamps), machining parameters: V=2500m/min, fz=0.12mm /z, Vf=14.3m/min; Piece, surface roughness Ra0.8, flatness <0.004mm, the beat meets the requirements.
(2)Composite machining tool Composite machining is a very effective means to improve machining efficiency. Several machining contents are completed in one process with one knife, which reduces the number of tool changes, saves auxiliary time and improves production efficiency. Step drill is the simplest and most common type of compound machining tool. The drill with chamfering edge is the simplest step drill. In the processing of the cylinder block and the cylinder head hole, the simple step drill is selected for the drilling process in which the hole needs chamfering, and good results are obtained. For example, Kenner's straight groove 180° apex angle TX step drill bit has almost zero radial force when drilling, and four linear lands are symmetrically distributed along the circumference. It has good guiding properties and has a light-reducing effect to make the straightness of the drilling. And the degree of position has been greatly improved. In the machining of cylinder block and cylinder head hole, the other compound drill bit is a TF drill bit with three cutting edges on the circumference. The drill core is thicker and stronger than the two-blade drill bit, which makes up for the weakness of the hard alloy toughness. The special shape of the front end of the tool tip can be self-centering without machining the center hole; the cutting edge increases the feed per revolution (up to 20m/min when cutting aluminum), high strength, high-speed cutting (cutting aluminum) The maximum time is up to 1000m/min), which greatly shortens the processing time and improves the processing efficiency. It is especially suitable for deep hole machining. The dimensional accuracy is up to H9, the positional accuracy is up to ±11μm, and the roughness is Rz20~25.
In the Great Wall crankshaft production line, Kennametal solid carbide SE step drill is selected, which has higher drilling roundness than ordinary high speed steel drill. The drilling roundness of high speed steel drill can reach 20μm, and SE drill bit The roundness of the hole is only 1/5 of the former. According to the accuracy of this hole shape, we can completely consider the process of eliminating the reaming. In some cases, it can even replace the reaming that is not required (such as the threaded bottom hole of the extruded thread). The drill bit is characterized by a shorter cross-edge grinding and reduces the axial force by nearly 50%; the rake angle near the core is positive, so the cutting edge is sharper; the groove shape is parabolic, and the core thickness is larger. The drill bit has higher strength and stronger rigidity; there are two injection cooling holes, and the cooling condition is good; the arc-shaped cutting edge and the chip flute type are arranged reasonably, which is convenient for the chip to be broken into small pieces and smoothly discharged. The drill bit is used for drilling the front and rear ends of the crankshaft with good results.
(3) Precision hole processing tools The rapid development of modern industry puts higher requirements on the dimensional accuracy, geometry and surface roughness of the hole, especially in the automotive industry, which requires high precision and requires large quantities, thus requiring high efficiency. Precision hole machining tool. Diamond reamer is a precision tool developed to meet this need. In the cylinder head production line conduit and the seat bottom hole, the Kennametal blade integrated welding PCD reamer was used; the cylinder head cylinder positioning hole was finished, and the Kenner Bencere split type indexable PCD reamer was used. High-speed and high-efficiency cutting has been realized, and the performance of the high-speed machining center has been fully utilized, which has greatly improved the processing efficiency. The actual sampling of some products in the field? 8, 10 and 13 three sets of holes, the size range of variation within 0.014, the maximum dimensional accuracy error is less than 60% of the tolerance, the average error is less than 0.005mm, the surface roughness of the hole <Ra0. 8.
The cylinder crankshaft hole finishing and the cylinder head camshaft hole finishing use the Kennamese BencereQUATTRO-CUT tool, and the 4-blade indexable insert is mounted in a high-precision sawtooth pocket with dimensional accuracy controlled at μ level. Compared to conventional split indexable tools, the QUATTRO-CUT tool only needs to adjust the radial height of the insert, eliminating the need to adjust the blade back cone and reducing the adjustment time. According to the sampling record, the crankshaft hole is finely tuned. Dimensional accuracy machining error <0.018mm, coaxiality error <0.016mm, minimum error only 0.0021mm, roughness <Ra1.6; fine camshaft hole, coaxiality error <0.007, minimum error 0.0014mm, roundness The error is <0.002mm, the position error is <0.063, the minimum error is 0.0148mm, the dimensional accuracy deviation is <0.018mm, and the minimum deviation is 0.0044mm. The processing of the two sets of holes can meet the beat requirements, and the trial processing has produced hundreds of pieces so far, with good results.
(4) Cylinder bore and crankshaft machining tool The cylinder block of the cylinder line of the Great Wall Company, the cast iron cylinder liner of the cylinder bore, the rough machining of the cylinder bore is a large amount of cast iron processing, which requires high strength and toughness of the knife. Consider using the Kenner Fix-Perfect tool. The Fix-Perfect tooling system is a product line with different positive and negative angle combinations. It features a negative radial rake angle and a positive axial rake angle. The positive axial rake angle reduces the axial cutting force and The negative radial rake angle creates a good shearing effect for chip breaking. The positive axial rake angle causes the cutting force to be directed toward the main shaft, which makes the milling cutter work more stable. Moreover, the negative radial rake angle can make the earliest "impact point" that cuts into the workpiece away from the cutting edge and protect the cutting edge. The blade is vertically mounted, and the lower part of the blade has a strong physical support, which increases the strength of the blade. Fix-Perfect tool processing accuracy, surface roughness are good, the only drawback is that the life is too low.
In the crankshaft production line, the KM tool system is used for the machining of the main journal and the front and rear end journals. The KM tool system was jointly developed by Kennametal Corporation of the United States and WIDIA of Germany. Its basic shape is similar to that of HSK. It also adopts a 1:10 hollow short cone fit and double-sided positioning. The main difference is the difference of the clamping mechanism. The KM shank is locked by the inclined surface of the steel ball. When clamping, the steel ball is pushed out along the inclined surface of the groove of the rod, and is stuck on the inclined surface of the locking hole on the shank. The shank is tightened to the spindle hole, and the shank is elastically deformed so that the end surface of the shank is in close contact with the end surface of the spindle. KM tool systems offer the advantages of high stiffness, high precision, fast clamping and easy maintenance. Tests have confirmed that the KM shank has a higher dynamic stiffness than the HSK system.
Coated carbide inserts such as KC9315 are used in the turning of the crankshaft main journal and the front and rear journals. The CVD composite coating has a thick K-MTCVD alumina layer, which is excellent in wear resistance and thick. KMTCVDTiCN coating ensures long life and can be used for high speed continuous cutting or slight interrupted cutting, especially for processing grey cast iron or ductile cast iron. In the crankshaft machining, the cutting speed reaches 223m/min, and the cycle meets the requirements, achieving high-speed, high-efficiency machining.
Steel Plate Punching Machine,CNC Sheet Metal Punching Machine,Steel Plate Hole Punching Machine,Metal Sheet Hole Punching Machine
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