Zhengzhou Bote Hard Material Tools Co., Ltd. is the only manufacturer of integrated boron nitride materials and tools capable of large-scale production of superhard materials and superhard tools in Zhengzhou. The company's overall PCBN high-speed face milling cutter has been promoted and applied in engine manufacturers, and it is the first company in China that can provide the tool.
In 2009, China's automobile production and sales ranked first in the world. With the continuous growth of the automotive industry in the past few years, the machining and metal cutting work related to automobile manufacturing has surged, and the automobile and its parts manufacturing industry has become the largest and most important user in the machine tool and tool industry. With the increasing competition in the market, improving production efficiency, shortening product delivery time and reducing costs have become the key to the survival and development of enterprises, and high-speed cutting is undoubtedly an important way to solve these problems. At present, high-speed milling has been gradually applied in the processing of automotive engine blocks, cylinder heads and other parts.
Advantages of high speed milling
The advanced processing technology of high-speed milling is still in the development in China. It has remarkable superiority compared with traditional processing. It can save tool materials and cutting fluid, save labor, save natural resources and reduce pollution to the environment. It is recognized as 21st century manufacturing. Key technologies for sustainable development.
High-speed milling allows the feed rate to be increased by 5 to 10 times compared to conventional milling, and the material removal rate per unit time can be increased by 3 to 6 times, and the machining time is greatly reduced. Secondly, high-speed milling uses extremely shallow milling depths and narrow milling widths. Compared with conventional milling, the cutting force can be reduced by more than 30%. When processing thin-walled parts such as cylinder heads with poor rigidity, the machining deformation can be reduced. . In addition, the excitation frequency generated by the high-speed rotation of the tool is far away from the natural frequency of the process system, and does not cause forced vibration of the process system, which can ensure a better processing state, thereby maintaining the dimensional accuracy, and at the same time, the cutting failure layer becomes thin and residual. The low stress enables high-precision, low-roughness machining and achieves the goal of milling.
Liu Shufeng, General Manager of Zhengzhou Bote Hard Materials Co., Ltd.
At present, high-speed milling technology has been widely used in industrialized countries and has achieved great economic and social benefits. In China, high-speed milling is still in its infancy.
High-speed milling technology and tool status of engine block and cylinder head in China
High-speed milling technology and tool status
Traditional engine block and cylinder head milling processes use a large number of special machine production lines, which have low production efficiency, slow production tempo and high production cost. Nowadays, with the continuous adoption of new equipment and new processes, the milling of engine blocks and cylinder heads gradually The use of CNC high-speed machining centers to replace these traditional special machine production lines, in the direction of high-speed milling, the spindle speed of many machining center machines has reached tens of thousands of revolutions. In addition, in order to improve production efficiency, gradually reduce or merge the processing steps, such as eliminating semi-finishing, rough machining directly after finishing, rough milling after surface rough milling to meet the requirements, and cutting out the machining allowance as much as possible in rough milling The amount is then finished to ensure the size and shape of the machine, positional accuracy and surface finish quality.
With the popularization of CNC equipment and high-speed milling technology MyCIMT, tool materials have also undergone tremendous changes. In recent years, in the engine block and cylinder head processing, various milling cutters mainly made of hard alloy materials have been used instead of the traditional high-speed steel cutters. The milling speed is greatly improved, the machining efficiency is improved several times, and the milling processing is comprehensive. Entering the high-speed milling stage played an important role. With the development of coating technology, the wear resistance and toughness of cemented carbide tools have been greatly improved. At present, the coating ratio of foreign carbide indexable inserts has reached more than 70%.
In addition, with the continuous improvement of the composition and pressing process of ceramic materials, the variety of ceramic and cermet tool materials has increased, the strength and toughness have been gradually improved, and the application fields and processing scope have been expanded. The finishing of the engine gray cast iron cylinder block and cylinder head In the semi-finishing process, it can replace the hard alloy, and the cutting speed can reach 2-5 times of the cemented carbide tool, which improves the processing efficiency and product quality.
In recent years, as engine block and cylinder head milling have progressed to higher milling speeds, carbide tools and ceramic tools have been difficult to meet the requirements of use, especially when the milling speed reaches 5000 m/min or more. PCD) and polycrystalline cubic boron nitride (PCBN) will be the two superhard tool materials found to date and available.
PCD tool material has high hardness, high wear resistance, high thermal conductivity and low friction coefficient. It can realize high speed, high precision and high stability processing when milling aluminum alloy cylinder and cylinder head on the end face, such as aluminum matrix. The cutter head and the 100mm six-tooth high-speed milling cutter have a maximum cutting speed of 7000m/min and a long service life.
The hardness of PCBN material is second only to diamond, and it is inert with iron. Especially its red hardness is good. It can maintain its hardness and good cutting performance at high temperature of more than 1000 degrees. It is suitable for high-speed milling. The cylinder block and cylinder head have achieved good application results, and can achieve “milling grindingâ€, which can increase the cutting speed by an order of magnitude compared with cemented carbide tools.
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