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Bimetal engine blocks (typically aluminum alloy block + cast iron liner) are widely used in modern automobile engines to balance weight reduction and wear resistance. However, boring bimetal engine cylinder bores presents the following machining challenges:
* Boring Aluminum alloy at the bore entrance is prone to produce built-up edge, leading to dimensional deviations and inconsistent machining quality;
* Cast iron liner bore requires high dimensional accuracy, tight form tolerances, and excellent surface finish;
* There is a demand for long tool life and high machining efficiency.
As a trusted partner, Worldia offers customized PCBN tooling solutions to address customers’ machining challenges and needs. These solutions help improve productivity and reduce machining costs for bimetal engine bore boring operations.
Fundo da aplicação
Based on the customer’s semi-finishing and finishing allowances and cutting conditions, Worldia’s solution adopts specially designed micro-edge inserts to reduce the formation of built-up edge at the bore entrance, ensuring machining precision and surface quality.
The insert used in the Worldia solution is made from PNS0117 garde, a high-CBN-content grade offering excellent resistance to chipping and outstanding chemical stability, which helps achieve longer tool life.
Compared with the original solution, Worldia’s customized PCBN tooling solution significantly improved tool life in both semi-finishing and finishing of the cylinder bore. It reduced tool changes and downtime, improved machining efficiency, and lowered overall processing costs for the customer.