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Turbo charger

Reduced fuel consumption and CO2 emissions with maintained performance is the challenge that automotive engine developers face today. A turbocharger is a turbine-driven device that increases the engine power by changing the oxygen ratio in the cylinders to improve combustion. The complex nature of the systems require manufacturing precision to enable maximized efficiency and downsizing of the engine.


Machining challenges

The material on the hot side of the component must withstand temperatures around 1300°C, why austenitic stainless steel is a common material in gasoline engines. Machining of the abrasive material is often characterized by extremely short and irregular insert tool life, uneven wear and difficulties meeting the tight work piece-tolerances.

Face milling cutter for machining of turbo exhaust housings

The new M612 face milling cutter is developed exclusively for machining of turbo exhaust housings. The positive geometry and the edge line quality ensure a reliable performance and an increased number of components per insert.

Short facts M612 face milling cutter:

  • For challenging roughing operations
  • The positive geometry provides smooth cutting action, which lower the power consumption and eliminate vibrations
  • 12 cutting edges, six on both sides, for reduced cost per part
  • Round inserts for increased flexibility and a high metal removal rate




​​Ordering code

 Insert
​ 612N-1260E-MM GC4240
​ 612N-1260E-MM GCS30T

 

Cutter body

DCX​
​50​ 612-050Q22-12HX ​​6
​63​ 612-063Q22-12HX ​8
​80​ 612-080Q27-12M ​8
​100​ 612-100Q32-12M ​10

 

Screw reference 5513 020-30

 


Solution - high pressure coolant

Increasing the coolant pressure has a positive effect on both chip breaking and tool life. CoroTurn HP is designed with fixed nozzles to enable high precision of the coolant supply at the cutting edge of the insert - a direct route to excellent chip breaking, process security and high productivity. To optimize the machine capabilities and further improve tool life and chip formation, coolant delivery and velocity can be fine tuned by changing the nozzle diameter.

Read more about high pressure coolant

 

The coolant jet has three main effects:

  • To provide cooling of the insert in the contact zone
  • To quickly force the chip away from the insert face, reducing wear on the insert
  • To help break the chip into smaller pieces and evacuate it from the cutting area

For rough turning, a coolant pressure of 100 bar provides a tool life that is twice as long as with 15-20 bar. For semi-finishing and finishing, as much as seven times as long!

 

Tool life comparison, finishing operation

Material: Austenic stainless steel (CMC 20.11)
Insert: CNMG 120418
Grade: GC1010 SF

 
15 bar
100 bar
Time in cut (min)
4.54
33
Wear (VB)​
0.62
0.3

Tool life × 7

By applying a coolant pressure of 100 bar, tool life increased by seven times in the finishing operation. Please also note that the wear value (VB) is lower after 33 minutes in cut with 100 bar pressure, than after less than five minutes with a conventional coolant pressure of 15 bar. For the roughing operation, tool life increased by approximately 40% when using high pressure coolant.

 

Time in cut (min)

 

15 bar pressure

100 bar pressure

Recommendations

The following cutting data is an example, where the material is austenic heat resistant casting stainless steel GX40CrNiSi2520, 1.4848 with 200 HB (CMC code 20.11). We recommend a Coromant Capto® tool holder for best stability and modularity. Apply a coolant pressure of 100 bar and use negative inserts in all operations for best results. A CNMG insert GC1010-SF is the first choice for both roughing and semi-finishing.

With conventional coolant pressure of 15-20 bar, use positive CCMT inserts in grade GC2025-MR or GC1010-SF for both roughing and semi-finishing for best result.

 

 
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