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Cylinder head

The cylinder head conveys air, plus gasoline or diesel to the combustion chamber and serves as a cover for the cylinders. In most four-stroke engines it also mounts the valves, camshafts and work as framework for a number of other components. It therefore needs to be strong and rigid. Thanks to the high thermal conductivity and low weight, the cylinder head is normally alloyed with aluminium.


Machining challenges

The greatest challenge when machining cylinder heads is to minimize the cycle time and at the same time produce components with close tolerances and a defined surface quality. Deburring, irregular tool wear and unpredictable insert tool-life typically provide long cycle times in the face milling operation.

Solution

The Sandvik Coromant M5B90 is designed with a unique axial and radial positioning of the inserts, which allows each insert to instantly cut chips efficiently without any insert adjustments. Each cutter is tailor made for each component, enabling an optimized number of cutting inserts, where one is always a wiper to ensure outstanding surface quality. High feed machining is therefore possible with a reduced number of teeth compared to conventional cutters.

 


 

 


Success story

A Spanish manufacturer of cylinder heads for passenger car engines asked Sandvik Coromant for help. The machining process was unstable and they had problems with burr. Another problem was the unpredictable insert tool-life, which depended on the cartridge adjustments that differed slightly from set-up to set-up.

 

Challenge

Provide a stable and burr-free machining process with predictable insert tool-life.

Quality requirements

Rougness (R): 4 (Rmax: 20)
Waviness (W): 4
Flatness: 0.05 

 

Solution

The Sandvik Coromant M5B90 offers a smooth finishing operation with predictable wear and no burr. As the cutter provides thin chips, they are easily removed from the component to avoid damaging of the face in the subsequent operation.

 

Existing cutter M5B90
No. of teeth169
Cutting speed, vc3140 m/min3800 m/min
Spindle speed, n5000 rpm6000 rpm
Feed rate, vf8280 mm/min9000 mm/min
Depth of cut, ap0.5 mm0.5 mm
Tool life30000 in average45000

 

With an optimized number of inserts that are always correctly positioned on the cutter, the customer can speed up the cutting data and save money on both a limited number of inserts and reduced cycle time.

Yearly saving: 21 000 €

 
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