Tool application case
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
Figure 1: KSCM-AluMill face milling cutter
In the cylinder and cylinder head production line, we use the Kenneth KSCM-AluMill face milling cutter for the face milling of aluminum alloy cylinders 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 of the cylinder are finely milled as an example. The top surface of the milling cutter Φ100, Z12 (9 fine milling cutter holders, 3 polishing cutter 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. Surface finishing cutter Φ200, Z24 (18 finishing cutters, 6 polishing cutters), processing 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.
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