High stability is the core factor in finish machining of gray iron cylinder hole in auto engine production line, which requires high precision, surface roughness and stability for the hole; the cutting speed is very high V≥ 500m/min) and long life of the cutting tools(machining qty ≥ 1000 ,meanwhile,chamfering,rough and finishing boring have to achieve the durability requirement), owing to fast cycle time of the production line.Consequently,if taking PCBN cutting tools, it is available to reach high speed cutting and stability for machining of auto engine cylinder hole, its classic cutting parameters as V=500m/min; f=0.2~ 0.4mm/r; ap=0.2~0.7mm.On the other hand, for high speed,stability,surface roughness and mirror finishing machining of the non-ferrous metals, we usually take PCD cutting tools to do this work, due to its high hardness, low affinity between the cutting tool and work-piece surface,meanwhile,as the cutting tools generally are polished with mirror finish to avert chip built-up problem, resulted in size-stability, good surface roughness and long cutting tool service life. For instance, using PCD cutting tools to process motor ballast’s copper commutator with classic cutting parameter as V=300m/min f=0.08mm/r ap ≤ 0.15mm,machined surface roughness Ra0.1~0.2,and tool’s service life >5,000pcs,however,if taking to do that with tungsten carbide tools, which is only capable to machine several pieces.
In the meantime, if taking PCD cutting tools to process various aluminum-silicon alloy parts, its surface roughness available to get Ra ≤ 0.1and tools’ service life at thousands pieces, especially which are extremely suitable for massive production of auto and motorbike components. If taking single-crystal diamond cutting tools, it is available to realize sphere mirror machining on the ultra-precision lathe, which uses ultra precision aerostatic spindle and rotary table, runout≤ 0.3um, workpiece fixed with high precision pneumatic chuck to accomplish fast and high precision positioning. On the other hand, when machine copper materials without oxygen with PCD cutting tools ,its surface roughness available to get Ra ≤ 0.025,runtout≤ 0.3,for aluminum materials, Ra ≤ 0.025.
Lastly, taking PCBN cutting tools to process boron -casting iron cylinder with dry and clean machining, its cutting parameter as V=200m/min,f=0.1mm/r ,ap=0.2 1mm,Ra≤ 1.6 and tolerance as h6,in addition its service life is capable to reach >100pcs after 2-times resharpening,denoting a achievement of turning instead of grinding process and accommodate the requirement of clean-production.
