We have designed several different processing schemes for trial cutting. After analyzing the trial cutting results, we believe that there are two main reasons for restricting the efficiency of cylinder bore machining:
Cutting vibration
The cutting vibration generated when the cylinder bore is rough increases as the cutting speed increases, which limits the increase in cutting speed. Moreover, the cutting vibration causes the blade to be easily damaged, and the tool change is frequent, resulting in a decrease in the starting rate of the device.
2. High spindle load
The Brilliance 1.8T series engine is an all-aluminum engine. The machining is mainly based on aluminum processing, which saves energy and reduces equipment capacity. The production line does not use a high-power machining center. Therefore, the machine is operated at full load while machining the cast iron cylinder bore. Due to machine power limitations, material removal rates cannot be increased by increasing the feed rate or increasing the number of cutting inserts.
Make effective improvements
In order to reduce the cutting force, eliminate the cutting vibration and improve the machining efficiency, we cooperated with a tool manufacturer to design a new type of cylinder hole roughing boring tool (see Figure 5). Compared with traditional boring tools, the new boring tool has the following advantages:
Figure 5 New cylinder hole roughing boring tool
Cutting angle
(1) Positive rake cutting
It is generally considered that tools that process brittle materials such as cast iron should use a negative rake angle to increase tool strength and prevent tool chipping from being damaged. However, among the various geometric parameters of the tool, the rake angle has the greatest influence on the cutting force. The other the conditions are the same, the larger the rake angle of the tool, the smaller the cutting force.
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