As we all know, although the procurement cost of the tool only accounts for a small share of the manufacturing cost of the entire component, it has a direct impact on the machining accuracy, processing efficiency and manufacturing cost of the workpiece.
For many years, Unimoco Ltd. (UNIMERCO) has maintained close cooperation with world-renowned automobile manufacturers. For the hole machining of copper or aluminum alloy, UNIMERCO's new diamond tool - spiral groove PCD reamer can effectively solve the problem of short life of hole machining tools, and meet the high-volume production needs of the automotive industry.
UNIMERCO is a custom tool manufacturer specializing in customer process optimization with more than 40 years of history. The spiral groove PCD reamer series is one of its most innovative achievements. The most important feature of this patented product is that the linear edge of the PCD insert and the spiral of the flute are perfectly combined by high-precision machining and welding, and the chip is guaranteed under high-speed rotary cutting of tens of thousands of revolutions. The problem of smooth discharge. Compared with ordinary PCD reamer, it is characterized by better guiding performance, better light-repairing performance, smoother chip removal, and processing efficiency can be doubled.
Here, let us further understand this new tool through two actual machining cases.
typical application (1) Processing the engine cylinder head tappet hole Due to the complex structure of the engine and the high technical content, the manufacture of its components has always been the focus of attention.
When finishing the cylinder head tappet hole, the short tool life has been plaguing the technicians who produce the first line. After close cooperation with a domestic automobile company, UNIMERCO has successfully developed a new type of fine reamer for processing the light alloy engine cylinder head tappet hole, which effectively solves the above problems.
UNIMERCO's reamer has a spiral structure with 2 cutting edges and 6 guide strips. Practice has proved that this product not only solves the problem of burr, but also compared with other PCD tools, its common cutting parameters have been greatly improved: the roughing allowance is 0.35mm on one side, and the finishing speed is n=10000r/min. The feeding rate Fn=3200mm/min, the retracting feed rate is 6000mm/min, and the life before grinding can reach 150,000 holes stably, almost achieving burr-free and achieving mirror effect. Compared with the cutting parameters (Fn=1800mm/min, Fz=0.045, lifespan of about 70,000 holes) that the automobile company originally used other tools, the efficiency has been significantly improved.
(2) Machining automatic transmission slide valve hole This is the application case of UNIMERCO tool in the processing of the automatic transmission valve body sliding valve hole of a famous European company.
The machining of the automatic transmission valve body spool valve hole is the most demanding station in the entire box hole machining process. In the processing of aluminum alloy valve bodies with a common silicon content of 8% to 16%, the tool solution commonly used by UNIMERCO is a combination of two knives of "one coarse and one fine".
1 roughing: UM PCD straight slot reaming knife. The processing speed is n=8000r/min, and the feed rate Fn=0.3mm/min.
2 Finishing: UM PCD spiral groove reamers are used. The processing speed is n=10000 r/min, and the feed rate Fn=0.5 mm/min.
With the "one coarse and one fine" processing scheme, the machined surface has a very ideal mirror effect, which can achieve a surface roughness of Ra 0.08 ~ 0.20, and the tool life can be stabilized to 80,000 holes before grinding.
Conclusion Now, the new tool product developed by UNIMERCO has been recognized by users and is widely used in automatic transmission valve body sliding valve hole, shift lever hole, cylinder head tappet hole, valve guide hole, positioning hole, fuel injection pump plunger hole. , Steering valve spool holes and other precision finishing holes in the finishing process.
The main features of this new type of tool are: 1 suitable for processing with interference holes; 2 very good light and directivity, thus ensuring high roundness, cylindricity, and smoothness requirements; 3 excellent deburring function, basic No special follow-up deburring process is required; 4 processing efficiency is usually 3 to 8 times that of straight-groove tools, which directly reduces customer equipment and personnel costs.
In addition, as the world's leading manufacturer of high-end non-standard PCD and carbide custom tool and supplier of optimization solutions, UNIMERCO can not only provide satisfactory services for the majority of users, but also can use solid carbide tools according to the actual situation of different users. Combine with PCD tools or other standard tools to process Team Work, which complements the advantages of various tools in metal processing and helps users achieve good overall benefits.
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Yucheng County Ruiertuo Tools Co., Ltd. , https://www.ruiertuotools.com