Application of the hottest Tiger Blade in engine p

2022-08-12
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Application of Tiger Blade in engine machining

tiger Tec is a new type of cemented carbide coated blade specially developed by Walter Co., Ltd. for processing cast iron. As we all know, the cylinder block of the engine is mostly made of gray cast iron. Before the appearance of Tiger Blade, in order to ensure the stability and efficiency of processing, many engine manufacturers used ceramic blade to process the cylinder block. MAHLE is a manufacturer specializing in motorcycle engines. They also believe that cemented carbide cutting tools are difficult to meet their processing needs. Their cylinder holes are made of gray cast iron similar to HT250 (its internal brand is niresist). The rough boring hole diameter is 80mm and the length of the hole is 150mm. In rough boring with a single side allowance of 2mm, the special double-edged boring cutter and the ceramic blade sngn120712 SL500 of a company are used (they sometimes use the blade of sngn120716 due to the need to control the cutting force), and the service life of the machined tool is 70 workpieces. The company that supplies their ceramic blades is the leader in ceramic blade technology in Europe and has a high competitiveness in ceramic cutting tools. Since 2000, the local Walter engineer recommended to them the blade snma120416 wak10, which did not produce toxic and harmful gases when the tiger burned. What surprised them happened. Although the cutting speed of tiger blade at 375m per minute is slightly lower than that of ceramic blade at 500m per minute, its machining efficiency is slightly higher than that of ceramic blade (1.25%) because the feed rate is increased from 0.2mm per tooth to 0.27mm per tooth. Under such conditions, the service life of Walter tiger blades can also reach 70 pieces stably, sometimes even 80 pieces. It can be said that compared with ceramic blades, the service life is not inferior at all. At the same time, due to the toughness of cemented carbide blade is higher than that of nitride ceramics, the tiger blade has not experienced the usual edge crushing phenomenon so far, and MAHLE's processing personnel no longer need to constantly monitor this closely. As the price of tiger blade is much lower than that of ceramic blade, MAHLE company has obvious economic benefits after adopting Tiger Blade. Before using the Tiger Blade of Walt, the annual cost of purchasing the blade of this process was about 51000 euros. After using the Tiger Blade, the cost of processing the blade of this process has been reduced to 40700 euros, a decrease of more than 20%. Through this technological revolution, MAHLE company not only directly reduced the purchase cost of cutting tools, reduced the risk of cutting edge collapse in processing, but also reduced the variety of cutting tools (two different tool tip arc radii are no longer required). At the same time, increasing the tool tip arc radius also improved the level of surface roughness, thereby reducing the grinding time of the subsequent process

Figure 1 MAHLE engine block

for those who used cemented carbide blades to process engine iron castings, tiger blades can generally significantly improve the production efficiency of engine manufacturers

GKN is one of the world's famous auto parts manufacturers. Their factory in Britain has an engine block production line. GKN UK factory has long used snma 150616-kr gc3015 blade of a famous tool company for rough machining of cylinder block, and the annual consumption of this blade is about 5000 pieces. Gc3015 is the world leader in the cutting tool industry, and its great achievements in the cutting industry are obvious to all. Before trying out the Walter Tiger Blade, many tool suppliers tried to replace the gc3015 blade there, but these attempts ended in failure. This situation makes the metal cutting experts of GKN UK factory even conclude that the gc3015 blade they use is irreplaceable, so that when Walter experts recommend Tiger Blade to them, they are unwilling to believe the power of Tiger Blade. However, after Walter experts fully introduced the successful experience of Tiger Blade and agreed to carry out the cutting test according to the conditions of GKN (these conditions are almost too harsh to imagine even by themselves), GKN British experts finally agreed to carry out the cutting test. The experiment was a complete success. When GKN UK uses gc3015 blade, it uses 170m/min cutting speed and 0.6mm/r feed rate to process, while when using Walter Tiger Blade, the cutting speed is increased to 285m/min, and the feed rate is also increased to 0.8mm/r, while the cutting depth is still maintained at the level of 5mm. We know that the requirements for cutting speed are usually the most stringent. A high cutting speed will mean a sharp decline in tool life. For example, if the cutting speed is increased by 25%, the tool life calculated by processing workpiece will be reduced by about 40%. However, after Walter's Tiger Blade improves the cutting parameters so much, the tool life in terms of workpiece processing still reaches the same level as gc3015. Although the price of tiger blade is much more expensive than that of gc3015, GKN UK factory still decided to replace gc3015 blade with Walter Tiger Blade due to the improvement of processing efficiency, which currently only solves the problem of dispersion in liquid. Because the processing efficiency of Walter tiger blade is increased to about 224% of the original gc3015, which saves a lot of processing costs. After deducting the increased cost of purchasing knives, GKN UK will reduce the manufacturing cost by £ 387300 per year

Sn turning blade

AP milling insert

Figure 3 Walter Tiger Blade

Figure 4 corresponding relationship between aluminum oxide coating thickness and crack condition

test conditions:

workpiece material gg26cr

dry cutting

45 ° main eccentric face milling cutter with a diameter of 125mm

sehw1204afn milling insert

.

ap=3 mm, ae=110 mm

john Deere is an American manufacturer of agricultural vehicles Companies of engineering vehicles and engines and their components. Some of their engine cylinder heads are made of cast iron. They originally used the 6k5a06r01 milling cutter of a famous company famous for milling cutters for finish machining. The milling cutter with a diameter of about 152mm uses 10 general blades (LPE) and 2 polishing blades (LPE wipers), and the blade material is 722. When using this milling cutter, they process with a cutting speed of about 274 m/min and a feed rate of 0.13mm/z, and a feed rate of 873mm/min. After using the Tiger Blade of Walter, the cutting speed is increased to 305m/min, the feed rate is maintained at 0.127mm/z, and the feed rate is increased to 965mm/min. Moreover, there is no need to polish the blade when processing with only Walter tools. John Deere's metal processing experts are very happy about this. Tiger Blade has become their only logical choice in this project. For this reason, they bought seven Walt milling discs at one time. Because of the use of tiger blades, their cutting tool costs have been reduced by 55%, and the overall processing costs have also been reduced by about 6.5% due to the reduction of cutting tool costs and the improvement of processing efficiency. Using Tiger Blade makes them reduce the processing cost, reduce the tool cost, improve the processing quality, and simplify the tool management

what makes Tiger Blade provide higher cutting speed than before when roughing cast iron? The technical department of Walter company made its own explanation. They said that first of all, plating technology played a major role. The practice shows that the black aluminum oxide coating is undoubtedly the best choice when processing cast iron, especially rough cast iron. Moreover, we can see from Figure 4 that the thickness of alumina coating is inversely proportional to the occurrence of comb cracks. However, because the thick coating will damage the adhesion of the coating, the conventional coating of the tool is generally thin. The R & D personnel of Walter Tiger Blade have developed a special intermediate layer through a large number of research and tests, which improves the adhesion of the coating and allows the coating thickness to be increased, so that the more durable aluminum oxide coating has been brought into full play. At the same time, the cemented carbide matrix has also been further improved to make it more wear-resistant. The high cutting speed and process reliability of tiger blade are largely attributed to the combination of alumina coating and improved tungsten carbide matrix through a special intermediate layer. It is worth noting that the test results in mapbingen, where the headquarters of Walter group is located, show that the improvement of wear resistance and the alleviation of comb cracks make the cutting of Tiger Blade devote to the research and development of energy-saving and environment-friendly high-function materials, and the performance has been fully improved. This is why Tiger Blade has super wear resistance when processing cast iron

the color matching of black and gold is also highly practical. Joerg drobniewski, who participated in the development of Tiger Blade by Walter company, said: "there is no doubt that cemented carbide blade with aluminum oxide coating should be the first choice when roughing cast iron. Its main disadvantage is that the black coating makes the wear trace difficult to identify." According to Joerg drobniewski, this is the magic weapon of the Tiger Blade: "through the black front knife surface and the gold rear knife surface, we can effectively identify the wear of the knife"

through the tiger blade used for roughing cast iron, Walter company has achieved a great change. Generally, famous cutting tool companies in the world have competitive advantages in some aspects. Our case comparison shows that our specific products are more suitable than the competitors' products originally used by customers in those occasions. At least in terms of performance in practical application, Tiger Blade has achieved a leap forward development in processing coated cemented carbide blades of cast iron, reaching the cutting efficiency and service life previously achieved only by ceramic blades, and has obvious competitive advantages in economic benefits

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