Jinwu Glass Fiber Co., Ltd , https://www.jwglassfiber.com
Wang Wei, Technical Director of Seco Tools (Shanghai) Co., Ltd. recently introduced some successful application cases of Seco's new X-Fix reamers in the automotive industry to the experts and scholars at the 2011 Shanghai University Advanced Manufacturing Process and Tool Technology Symposium. . According to reports, this reamer successfully achieved the combination of the highest feed rate, highest performance and highest precision. Its modular construction of the shank, the wide range of extensions with Capto and Graflex systems enables reaming depths of up to 6.5XD, and the reamer's inverted cone is supplied by a precision-made insert holder, so no adjustment is required . The X-Fix reamer has 8 cutting edges for turning into blades, each with a blade diameter ranging from 40mm to 155mm; multi-tooth for high feed performance for high-volume machining. To set the diameter, the blade can be fixed with just one screw, and the only setting to remember is 25μm. The patented preloaded guide strip system ensures the stability of the cutting process and ensures reliable tool life. The quality and safety of the machining operations are guaranteed and the tool cost management is simplified. To reduce inventory, the user can use the same insert for all Xfixes (from 31.5 to 60.5 mm diameter) and does not require regrind. Stable tool life, the latest coating technology and the low cost of each blade reduce the cost of XfixTM reaming.
Advanced tools can greatly improve the processing efficiency of automotive engines
Today, global automakers are striving to produce more economical and energy-efficient cars, and they have many ways to cut costs to achieve this goal. New materials are available for the cabin; for the chassis, a universal, modular "platform" and more standard parts can be manufactured; for Accessories and electronics, more sophisticated components can be developed. According to statistics, two-thirds of the investment in the automotive industry is used to purchase equipment for automobile manufacturing. Among them, the tool is the most direct tool to “close contact†with the part being processed, which has a very direct impact on the quality and manufacturing cost of the final product. In the case of car production, the consumption of tools only accounts for 3% of the manufacturing cost, but it affects 25% or more of the total manufacturing cost. For the 50 million passenger car manufacturing program this year, if every component can save a penny, the entire automotive industry will be able to cut the cost of 8 digits. Strict economic requirements and safety requirements, for auto parts suppliers, there is an urgent need for new and more advanced processing tools, "spiders" entangled in many complicated factors such as cost, profit, efficiency, safety, energy saving, etc. In the "net", a "benefit" road is drawn. Engine Processing: The Key to Lowering Costs According to IRN, Inc. of Detroit, USA, engine production costs account for 17% of the total production cost of passenger cars, but none of the above cost reduction methods are applicable. Gasoline engine production, by contrast, is the most complex, demanding, and costly component in the automotive production process. The engine is generally a self-produced part of the enterprise, and there are certain limitations in the design improvement. In the actual use of high temperature, high pressure environment, it is also determined that the engine can only choose metal materials. Even with the most advanced production technology, due to the strict tolerance requirements of the engine itself, metal processing is inevitable in any case, including the processing of cast iron. For example, machining cylindrical holes, in order to achieve high metal removal rate, must ensure that the dimensional tolerance band is controlled within 0.01mm, roundness and cylindricity (regardless of relative value or absolute value), during finishing, the geometrical tolerance is 0.001mm . For the above reasons, in the complicated manufacturing process of engine components, the machining of engine cylinder bores has become a bottleneck for breaking high costs, and how to reduce the processing cost has become the direction of various manufacturers. A large number of stepped holes of different sizes, complex internal surfaces and small deep oil holes require extremely high machining accuracy, which is the processing of all tool structures, main cutting edge shapes, tool materials, coatings , and chip breaking and chip removal. Performance puts higher specific requirements. Engine cylinder bore machining typically involves three steps: roughing, semi-finishing, and finishing. Breaking this processing bottleneck is very effective in reducing the cost of automobile production. Shortening the machining cycle of one hole means that the machining cycle of the remaining 3, 5 or 7 holes is reduced (the number of holes depends on the engine model). Using advanced tools to increase efficiency and reduce costs. A large German automobile engine production plant, in the processing of its engine cylinder bore, the first application of the tool is to process the GG25 gray cast iron sleeve, which will be pressed into the cast aluminum engine block. . This step requires widening the hole with a depth of 138 mm from 74.50 mm to 76.10 mm. Although the step is called “cylinder holeâ€, the machining process is closer to the vertical boring and milling; the tool diameter is made according to the final diameter of the cylinder bore, and the way of feeding along the Z axis ensures the high coaxiality of the machined hole. At the time of initial processing, the plant used special tools for roughing and semi-finishing. Both the roughing and semi-finishing processes are performed by clamping a CBN blade with a 5-blade to a milling cutter with a fixed sipe . The machining cycle is as long as 16.6 s; the two-step tool also performs poorly on the problem of chip removal, and the re-cutting of the chip is not conducive to finishing and wears the cutting edge. The automaker wants a more cost-effective alternative: looking for more reliable machining methods based on the original process, dramatically reducing cycle times and ensuring the quality of the workpiece surface. In response to this situation, Isca Tool's solution is to use two clamping methods on the same body, clamping coated carbide inserts, one form for roughing, and another for roughing. A knife seat form for semi-finishing. Four roughing inserts are held parallel to the top surface of the tool in the fixed sipe. The three semi-finished inserts are vertically clamped to the adjustable seat and distributed over the circumference of the milling cutter. The roughing blade set has an enlarged aperture of 1.00 mm; the semi-finished blade set has an enlarged aperture of 0.6 mm. The coolant passes directly through the inner cooling nozzle to the cutting edge of the insert to ensure effective chip evacuation. To reduce chatter, the semi-finished blade sets are distributed circumferentially in an asymmetrical manner. At the same time, the vertical blade, the blade and the pitch circle are arranged tangentially instead of being perpendicular to the pitch circle. The principle is to direct the main cutting force to the thickest blade section to increase the bearing capacity of each blade. The cutting load is directed at the body and provides longer tool life while effectively damping. In addition, the blade is clamped vertically and the screws are protected from tensile stresses, ensuring more reliable cutting. In addition, Iskar explores the factors that shorten the machining cycle by analyzing the customer's machine settings and updating the cutting parameters. Iskar did not change the speed of the machine, still 1,500 rpm, cutting speed Vc = 360 m / min, the blade removed material 0.50 mm per blade. Instead, the feed rate is increased from 0.07 mm/tooth to 0.10 mm/tooth, which significantly increases table feed and feed rates. After several months of trials of the new technology, the automaker found that with Isa's new specially developed tools, the cycle of cylinder bore machining was 44% shorter than before. With an engine with 4 cylinder bores, under the same cutting conditions, the roughing composite semi-finishing of each cylinder bore was shortened from the original to 16.6 s to the current 9.2 s. At the same time, the number of tools used in the process is also greatly reduced, helping users reduce blade consumption. Once you needed the steps of your own tool, you can now finish it with a single tool. Unexpected savings, in addition to the fact that coated carbide inserts are more economical than CBN inserts; and because of the vertical clamping of the inserts, each insert has more cutting edges, which together extend tool life. As another important component of the engine, the connecting rod and the crankshaft and the piston pin are required to have high precision, and the rough, fine, reaming and polishing processes are used, and the reaming precision and difficulty are the highest. An auto parts manufacturer used Seco Tools' new X-Fix large-diameter multi-tooth reamer when machining the big hole in the connecting rod. During use, the reamer has a diameter range from 40mm to 155mm, which is easy to use with IT6 tolerances. Moreover, the number of teeth of this reamer is more than that of the same type of tool, including the number of teeth of 3, 5, 7, and 9, which greatly improves the processing efficiency; and the tool processing process is very stable and reliable, greatly reducing the processing cost. The customer is very satisfied with this.