Blue Flag Metalworking: High-speed, efficient machining of engine 5C parts

The automotive engine, as the heart of the vehicle, presents complex structural challenges along with numerous machining difficulties. These issues are particularly evident in the critical components known as the "5Cs": cylinder block, cylinder head, crankshaft, camshaft, and connecting rod. Addressing these challenges while maintaining quality and enhancing productivity has become a key focus for leading tool suppliers. Among these solutions, the Feed-Jet high-speed face milling cutter developed by Lanzhi Metallurgy stands out for its exceptional speed, efficiency, and cost-effectiveness thanks to its ability to be reground and reused up to six times. Moreover, Kieninger, part of the LMT Group, has introduced a precision boring tool with an automatic compensation mechanism designed to deliver ultra-high geometric accuracy for cylinder bores. This tool leverages CBN cutting material to extend tool life and improve overall cutting economics. China’s automotive industry has experienced rapid growth over the past few years, with production rising from 18.26 million units in 2010 to 18.42 million in 2011, and continuing to grow in 2012. This expansion has placed increasing demands on automotive manufacturers, especially concerning the quality and efficiency of critical engine components like the cylinder block and cylinder head. As a result, there is a growing need for innovative tools that can meet these stringent requirements. The automotive sector's emphasis on fuel efficiency and performance has led to the widespread use of aluminum alloys, such as ALSi9Cu3 and GD-ALSi7, in engines, particularly in smaller displacement gasoline engines. Since milling constitutes around 40% of the machining process for these components, optimizing milling efficiency is crucial for improving overall production rates. To address this, Kieninger has developed the Feed-Jet high-speed face milling system, which boasts dense gear designs, a robust rack-type clamping structure, and micro-level adjustments. Its ability to be reground and reused multiple times makes it both efficient and economical. A notable case study involves a renowned international engine manufacturer, DC, where the Feed-Jet system was employed to mill cylinder heads made from GD-ALSi7 aluminum alloy. Using a tool diameter of 100mm with 16 cutting teeth, the system operated at 11,000 RPM, achieving a cutting speed of 3455 m/min, feed rate of 0.07 mm/tooth, and feed speed of 11,500 mm/min. With a cutting depth of 0.5mm, the tool demonstrated a lifespan of 15,000 workpieces without repair—three times longer than competitive offerings—and improved surface finishes to Rz=6.3, all while increasing processing efficiency by 30%. In summary, the Feed-Jet system represents a breakthrough in milling technology, offering unmatched speed, efficiency, and cost-effectiveness, making it ideal for aluminum alloy milling in cylinder heads and blocks. Keywords: cylinder head, cylinder block, precision boring, aluminum alloy finishing. This advancement underscores the continuous innovation within the automotive manufacturing sector, driven by the dual demands of quality and productivity. As the industry evolves, tools like the Feed-Jet system will play a pivotal role in meeting future challenges and opportunities.

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