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Mainstream passenger car gasoline engines typically adopt a classic and widely used structure: an aluminum alloy engine block with cast iron cylinder sleeves. However, the cutting tools used in machining this type of component require processing two materials with drastically different cutting characteristics using a single tool. As the tool transitions between aluminum and cast iron, fluctuations in cutting forces can easily lead to tool deflection and vibration marks. In addition, the tool must balance the machining properties of both materials to prevent built-up edge formation, minimize edge wear, and ensure effective chip breaking and evacuation. This ensures a small and uniform allowance is left for the subsequent cylinder bore finishing process.
As a tool supplier capable of delivering complete machining solutions for bimetal engine blocks, Worldia has previously introduced its FMP-BE milling cutter for machining the bimetal joint surface. In this case study, we focus on the application of Worldia’s carbide cutting tools in the semi-finishing boring process of bimetal engine block cylinder bores. This solution has helped customers significantly reduce tool costs while successfully replacing high-end imported tools.
Solution Analysis
* Worldia’s semi-finishing boring tool for cylinder bores is specifically designed to meet the process demands of bimetal machining. The tool holder features enlarged chip flute and optimized cooling and chip removal channels. This design significantly enhances chip removal and cooling efficiency, ensuring bore quality while preventing damage to the already-machined cylinder surfaces caused by chip scratching.
* Worldia’s tool solution takes into account the machining characteristics and allowance of both aluminum-alloy and cast-iron materials. It uses a more versatile carbide grade combined with advanced coating technology to enhance the insert’s resistance to built-up edge and wear. In addition, considering the remaining aluminum alloy at the bore entrance and bottom, a special chip-breaker geometry is adopted to improve the chip breaking ability while maintaining cutting-edge strength.
* Worldia’s customized cylinder bore boring tools, paired with coated carbide inserts, deliver a 50% increase in tool life compared to the original imported solution. This not only reduces tool costs for the customer but also enables successful localization of a critical machining process—replacing high-end imported tools with domestically engineered alternatives.