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Kyocera Tooling for Cylinder Head Machining – PT. Ikimura Indotools Center
KYOCERA’s unique cylinder head total touring program. Reduce the tooling cost significantly by composite machining and faster processing.
Features:
- Cycle time reduction by one-shot tool
- The integration of rough-finishing process by combination tool
- Achieve excellent chip evacuation by patented technology CFS
KYOCERA UNIMERCO – your full-service tooling partner
KYOCERA UNIMERCO offers a complete tooling programme for machining of cylinder heads. Selection of tools is always based on a cost-benefit assessment, thus the solution often includes both standard and customised carbide and PCD tools for pre-finishing and finishing applications.
High performance tooling solutions
To machine a cylinder head at the lowest possible costs you need the best possible combination of machinery, machining parameters and tooling solutions. Therefore, we analyse all aspects of the production process involving cutting tools and systematically optimise them. Subsequently, our tool developers define the optimum tooling solution customised to fit your requirements. Often, we are able to implement a solution which reduces the number of tools necessary for a certain operation or simplify the pre-machining, thus reducing overall tooling costs and machining time considerably.
All tools are developed and manufactured utilising the latest technology, and the optimum tooling solution often includes the unique UM DANDIA™ toolholding system which helps to ensure extreme accuracy and tight tolerances. The system also allows for unsurpassed high feed rates and long tool life.
EXAMPLE APPLICATIONS – INJECTION BORE COMMON RAIL
Kyocera Tooling for Cylinder Head Machining – PT. Ikimura Indotools Center
Objective:
Reduction of machining time by using fewer tools than the 3 tools that were used previously. The hole is made in solid material (no precasting). This makes it a great challenge for a one shot solution, since the large amount of chips often results in a surface finish worse than the Rz 6.3 required.
Unimerco tool solution:
CFS PCD step drill on solid carbide tool body with sandwich drill point. Adjustable UM Dandia™ toolholder to ensure optimum runout.
Tool no.: 210800/000005
Result:
By implementing a CFS tool, the hole is succesfully machined with a one shot solution, achieving a surface finish of Rz 1. This is possible because the CFS feature ensures that the chips do not get in contact with the hole surface.
The machining time is dramatically reduced. Using 1 tool instead of 3 eliminates 2 tool changes, 2×4 positionings, as well as 2×4 counterboring and reaming processes.
Achievements:
- 1 tool replacing 3 tools
- 33.8 seconds saved per cylinder head (478 hours/year)
Data:
- 10,000 rpm
- 3,000 mm/rev. feed rate
- Tool life 150,000 holes
- Tool costs = 0.06 euro/cylinder head
Kyocera Tooling for Cylinder Head Machining – PT. Ikimura Indotools Center
EXAMPLE APPLICATIONS – VALVE PARENT METAL FINISHING
Kyocera Tooling for Cylinder Head Machining – PT. Ikimura Indotools Center
Objective:
Reduction of cycle time. The customer previously used the same tool but with a straight-fluted reamer with no coolant outlets to the guide pads. The aim was a feed rate between 6 and 10 m/min. The straight-fluted reamer achieved a feed rate of 2.4 m/min.
Unimerco tool solution:
PCD combination reamer in adjustable UM Dandia toolholder. The reamer has negative spiral and cutting geometry. All chips are blown forward by the internal coolant. There are additional coolant outlets to the guide pads.
Tool no.: 710098/000491 – 492.
Result:
Feed rate for the reamer was increased by a factor of 3.3 from Vf 2,400 mm/rev. to Vf 8,000 mm/rev., both running at 10,000 rpm. Diameter tolerance is extremely steady, and roundness is within 4 micron. The increase of cutting data lead to a noticeable reduction of machining time, maintaining the same tool life.
Achievements:
- Feed rate increased by a factor of 3.3
- 4.2 seconds saved per cylinder head (51 hours/year)
Data:
- 10,000 rpm
- Reamer: 8,000 mm/rev. feed rate
- Counterbore: 2,500 mm/rev. feed rate
- Tool life 300,000 holes
- Tool costs = 0.01 euro/cylinder head
Kyocera Tooling for Cylinder Head Machining – PT. Ikimura Indotools Center
EXAMPLE APPLICATIONS – MOUNTING HOLE
Kyocera Tooling for Cylinder Head Machining – PT. Ikimura Indotools Center
Objective:
Increase capacity on an existing production line by reducing cycle time. The potential saving for the mounting holes was relatively big, as each of the 8 holes has a drilling depth of 96,5 mm. The holes are drilled from solid material (no precasting pilot hole).
Unimerco tool solution:
PCD spiral-fluted drill on solid carbide tool body with sandwich drill point. Adjustable UM Dandia™ tool holder to ensure optimum run out.
Tool no.: 210400/000030
Result:
The feed rate was increased to a remarkable 9,000 mm/rev. at 15,000 rpm. This is 3.6 times faster than the previous carbide drill which performed 2,500 mm/rev. at 8,000 rpm.
Even at these data, the process reliability is good. The ongoing tool costs are slightly higher than those of the carbide drill, but the savings from the reduced cycle time is several times higher.
Achievements:
- Feed rate increase by a factor of 3.6
- 22.70 seconds saved per cylinder head
Data:
- 15,000 rpm
- 9,000 mm/rev. feed rate
- Tool life not set yet (still running)
- Recommended cutting data:
- 10,000 – 15,000 rpm, fn 0,6
- (vf 6,000 – 9,000 mm/rev.)
- Decreased feed rate for first 8-10 mm
Kyocera Tooling for Cylinder Head Machining – PT. Ikimura Indotools Center
EXAMPLE APPLICATIONS – ROUGH MILLING OF CAM BORE
Kyocera Tooling for Cylinder Head Machining – PT. Ikimura Indotools Center
Objective:
To develop a cutter capable of higher feed rates and longer tool life than carbide insert cutters for the same operation. The operation involves milling from solid to half-round in one pass.
Unimerco tool solution:
PCD ball nose multi mill on steel body. The teeth are staggered with coolant supply to each tip. The cutter can be made both as a monoblock tool, as well as with a cylindrical shank for use in a toolholder.
Tool no. example: 430233/999999.
Result:
Compared to carbide insert cutters, this tool provides superior feed rates and tool life. Feed rate is usually set at 5,000 mm/rev. at 15,000 rpm. Examples have shown tool life of 8,000 – 10,000 meters of effective material cutting.
The dimensioning stability of the machined surface is very good, which ensures good process reliability in the actual process, as well as in the following reaming process. In direct comparisons with competing cutters, Unimerco’s cutters have shown 50-100% longer tool life.
Achievements:
- Greatly improved feed rate
- Reduced cycle time
- Improved process safety
Data:
- 15,000 rpm
- 5,000 mm/min feed rate
- Tool life 8,000 – 10,000 meters of cutting (equals 10,000 twin cam 4 cylinder head)
- Tool costs = 0.02 euro/cylinder head
Kyocera Tooling for Cylinder Head Machining – PT. Ikimura Indotools Center
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