Application Status and Development of Automotive Manufacturing Tools

Tool status

At present, the tools used in machining in the automotive industry are mainly superhard tool materials, such as high-strength cast iron parts, which are generally made of CBN, SiN ceramics, Ti-based ceramics and TiCN coated tool materials. The milling speed can reach 2200m. /min; processing high silicon (Si) cast aluminum parts using PCD, ultra-fine carbide tools, the milling speed can also reach 2200m / min, drilling and reaming speed can reach 80m / min and 24m / min respectively; processing The precision forged structural steel parts are machined with SiN ceramics, Ti-based ceramics and TiCN coated tools, and the turning speed is up to 200m/min. In addition, in the processing of various precision forged steel gears, high cobalt (Co) powder metallurgy high speed steel is used. The high-speed steel integral hob and shaving razor coated with TiCN on the surface, all kinds of broach processed on the inner and outer surfaces, the hobbing speed is 110m/min, the shaving cutting speed is 170m/min, and the broaching speed is 10 ~25m/min. 

In terms of tool use, HSK hollow short taper shank is mainly used on CNC machine tools, which can form high-speed tool system with various multi-blade special milling cutters and composite hole machining tools, and complete multi-process and multi-station cutting processing. Dynamic balance ≤ 2.5G; automatic detection device and semi-automatic compensation tool are widely used in the automatic production line of automobile parts. The automatic compensation tool for the fine cylinder bore introduced by Shanghai Volkswagen Automotive Co., Ltd. is an electric measuring instrument manufactured by Marposs, Italy. After the parts are processed, the machining dimensions are measured and compared, and the signal is sent to the automatic provided by Valenite. The compensation mechanism starts the stepping motor, changes the amount of the rising tool, and automatically compensates the tool; uses the automatic radial feeding tool to process the crankshaft hole of the cylinder block and the bearing stop pushing surface, and completes the boring of the hole and the end face in one pass, The perpendicularity of the end face of the workpiece to the hole and the parallelism of the end faces can be ensured. 

The future development trend is that high-speed (ultra-high speed) dry cutting technology will be widely used. The structural design and manufacturing technology of various types of tools, composites (combinations) or various types of high-speed cutting tools made of super-hard materials will become the leading technology for the development of tool varieties. Among them, the application of boring, squeezing and roll forming tools for chipless processing will be more extensive; the development of superhard tool materials will be faster and the application field will be expanded. 

Various types of car parts and the processing tool with machining holes Parts <br> <br> hole processing part mostly employed (clip blade machine, a combination of inserts welded) structure to the hinge, instead of squeezing cut composite multi-blade grinding . In the process of one-time walking, the hole finishing is completed, the rotation speed reaches 3000r/min, the cutting speed is 1.5~3m/min, the precision is 5~7, the roughness Ra=0.7μm, the gun drilling speed reaches 8000r/ Min, Ra = 2 μm. The precision boring and reamer produced by Mapal in Germany is widely used in the automotive industry due to its unique structure, ultra-precise internal hole precision, excellent surface roughness and high economic efficiency. The Mapal tool is a single-edged cutting tool with a precision ground indexable insert. Two or more supporting guide bars are arranged on the cutter body, and the support guide bars also support the corresponding positions at the same time as the blades enter the workpiece cutting, and absorb the vibration and resistance caused by the cutting, and ensure the inside. The roundness and cylindricity of the hole are within 1 to 3 μm, and the hole diameter tolerance is H6. In the processing of valve tunnel holes in automobile engines, the machining accuracy and surface quality are superior to gun drilling. The cylinder hole boring adopts double-station, machine tool spindle built-in and axial reciprocating push-pull rod mechanism. The reciprocating passes are used for rough and fine boring, respectively, and the boring speed is up to 800 m/min. 

<br> <br> machining plane for milling Parts Parts plane having a fine-toothed mostly employed, positioned over repeated clamp structure of radial and axial way adjustable-speed fine-toothed face milling cutter. The milling cutter has a diameter of 250 to 400 mm and an axial runout of ≤ ± 0.0025 mm. The machining of the part assembly plane is milled, with roughness Ra=0.7μm and unevenness <0.02mm. 

The insert of the fine milling cutter can be adjusted with an eccentric screw with an adjustment accuracy of 0.002 mm. In the medium feed finishing milling process, the normal blade and the smoothing blade are arranged reasonably, and the surface roughness of the parts can be obviously improved; when the large feed finishing is finished, all the polishing blades are used to obtain the ideal surface roughness. 

When milling aluminum alloy workpieces, various sizes of milling cutters with different pitches and large axial and radial rake angles are used. The rake face of the tool is polished, and the cutting force is small during cutting without vibration. Good quality.

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