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Tooling solutions for machining of cylinder blocks in ISO K and ISO N materials

 

Aluminum block

Cast iron block


The cylinder block is the component that serves as the main structure of the engine and the housing for several different moving parts that together generate the power to move a vehicle.

For many years, the engine block has been manufactured using cast iron alloys due to their strength, low cost and wear resistance. But as engines become more complicated, new materials have been adopted to reduce weight as well as to increase strength and wear resistance. Today's most common materials for passenger car engines are aluminum alloys because of their reduced weight and excellent casting properties. Commercial vehicles continue to use cast iron, but in higher-strength alloys.

The manufacturing process of cylinder blocks involves the largest number of machines in automotive component production. There are also several complex processes and tight tolerances involved. The high demands in quality for cylinder blocks are crucial for vehicles' performance. Cost-efficient manufacturing is of great importance for these types of components.

Besides our extensive offer, Sandvik Coromant also has dedicated products and engineered solutions that fully support overcoming the challenges presented by manufacturing these components.




Tooling solutions that support manufacturing cylinder blocks:


ISO K solutions

CoroMill® 745 – Multi-edge face milling cutter for best production economy

The patented insert positioning system provides the same light cutting action and performance as a positive, single-sided milling cutter, but with a total of 14 cutting edges.

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CoroMill® 425 – Finishing concept for cast iron face milling

Specifically designed for the automotive business. The accurate and reliable adjustment system makes CoroMill® 425 the easiest-to-use system on the market.

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CoroMill® 331 – Multi-purpose side and face milling cutter

CoroMill® 331 is a multi-purpose side and face milling cutter with high-precision capability for numerous operations. The cutter is the most productive of its kind for producing grooves and for parting off.

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CoroDrill® 460 – Multi-application drill

CoroDrill® 460 is a multi-application, high-performance drill that can be used across a wide range of materials. This drill provides high capacity utilization, flexibility and versatility.

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CoroDrill® 880 indexable drill

CoroDrill® 880, with its unique insert geometries and configuration, creates a balanced, step-by-step entrance into the workpiece. This reduces cutting forces to less than half that of typical insert drills and virtually eliminates deflection on entry.

Read more

 

CoroDrill® 400 and 430 – Flexible and precise drilling solutions

Customized tooling for the automotive industry. The straight-flute CoroDrill® 400 and 3-flute CoroDrill® 430 provide highly-productive hole-making in GCI, CGI and nodular cast iron, resulting in low cost per hole.

CoroDrill® 400
CoroDrill® 430

 

CoroTap® 100 KM – Straight-flute tap

Superior tool life and high productivity are just some of the benefits offered by this exceptional tool. Suitable for both through and blind holes.

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CoroTap® 200

CoroTap 200 features spiral point taps for through holes designed to push the chips forward. The range includes versatile taps for various materials and optimized taps for specific materials and applications. Tailor Made and Advanced Engineered tools are available from the Customized solutions range.

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CoroTap® 300

CoroTap 300 is a range of spiral flute taps suitable for tapping in blind holes up to 3 × D. There are different helix angles suitable for different applications. The range features versatile taps for various materials and optimized taps for specific materials and applications. Tailor Made and Advanced Engineered tools are available from the Customized solutions range.

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CoroTap® 400

CoroTap 400 is a high-speed, chip-free forming tap suitable for both through- and blind-holes in steel, stainless steel, aluminium and HRSAs. Versatile and optimized forming taps are available, with and without oil grooves, in an assortment of diameters, grades, coatings and thread forms to suit a range of applications.

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B685 – Stable and productive cylinder boring, from roughing to semi-finishing

Cylinder boring is a key operation in the automotive industry – a high-speed operation with high requirements on tight tolerances. Until now, the operator has adjusted the insert position manually, which is a time-consuming procedure and often requires special devices.

Read more

 

B687 – Stable and productive finishing cylinder boring

The B687 cylinder boring bar is designed for productive and stable finishing. The cutter is available in different designs, depending upon operation. Use the three-cartridge design for reliable performance in under-coolant applications.

Read more

 

B681 – Stable and productive roughing cylinder boring

B681 is designed and developed for roughing in cylinder boring operations. The solution produces excellent roundness and cylindricity, allowing for a smooth semi-finishing operation due to the integrated Silent Tools™ damped adapters.

More about B681 roughing cylinder boring

B681 roughing cylinder boring 

B683 - stable and productive semi-finishing cylinder boring

B683 is designed and developed for semi-finishing in cylinder boring operations. The solution produces excellent roundness and cylindricity, allowing for a smooth finishing operation due to the integrated Silent Tools™ damped adapters.

More about B683 semi-finishing cylinder boring

B683 semi finishing cylinder boring 



ISO N solutions


CoroDrill® 400 and 430 – Flexible and precise drilling solutions

Customized tooling for the automotive industry. The straight-flute CoroDrill® 400 and 3-flute CoroDrill® 430 provide highly-productive hole-making in GCI, CGI and nodular cast iron, resulting in low cost per hole.

CoroDrill® 400
CoroDrill® 430

 

CoroDrill® 880 indexable drill

CoroDrill® 880, with its unique insert geometries and configuration, creates a balanced, step-by-step entrance into the workpiece. This reduces cutting forces to less than half that of typical insert drills and virtually eliminates deflection on entry.

Read more

 

CoroMill® Century – Light cutting face mill for high-speed finishing

CoroMill® Century is a face mill tool system with an aluminum or steel body for high-speed machining. The tool is designed with a serrated insert interface for safe performance and reduced run-out.

Read more

 

CoroMill® Century – Bi-metal machining process without burring, chipping or scratching

Many modern engines use cylinder blocks that consist of gray cast iron liners casted together with aluminum. This makes machining engine block deck faces a considerable challenge.

Read more about bi-metal machining processes

 

M5B90 – Super finishing face milling cutter for aluminum

Finishing face milling concept developed for automotive aluminum components, such as cylinder heads, blocks, housings, covers and all components with a wide material engagement.

Learn more about the M5B90 milling cutter

 

M5C90 – One-shot face milling cutter for aluminum

M5C90 is a concept face milling tool for high-speed direct finishing of aluminum automotive parts, such as cylinder heads, cylinder blocks and all aluminum parts within a wide cutter engagement.

More about the M5C90 milling cutter

 

M5F90 – One-shot roughing and finishing of thin wall aluminum parts

M5F90 is a concept face-milling cutter that enables roughing and finishing of thin wall automotive aluminum components in a single operation.

More about the M5F90 milling cutter

M5F90 milling cutter 

M5Q90 – For first-stage roughing operations

M5Q90 cleans the surfaces of newly-casted aluminum cylinder heads and engine blocks in one smooth operation - without burring.

More about the M5Q90 milling cutter

M5Q90 milling cutter 

M5R90 – A new solution for roughing and semi-finishing of aluminum automotive parts

M5R90 is the First choice for roughing to semi-finishing in shoulder milling operations for automotive aluminum components such as cylinder blocks, cylinder heads and transmission housings.

Read more about the M5R90 milling cutter

 

M610 – New milling cutter for finishing bi-metal materials (Al and GCI)

M610 is a stand-alone product for the milling of bi-metal engine deck faces in engine blocks with GCI liners, bed plates with inserts in GCI, and all other automotive bi-metal parts with inserts in GCI. All without chipping, burring, or scratching.

More about the M610 milling cutter

M610 milling cutter 

B685 – Stable and productive cylinder boring, from roughing to semi-finishing

Cylinder boring is a key operation in the automotive industry – a high-speed operation with high requirements on tight tolerances. Until now, the operator has adjusted the insert position manually, which is a time-consuming procedure and often requires special devices.

Read more

 

B687 – Stable and productive finishing cylinder boring

The B687 cylinder boring bar is designed for productive and stable finishing. The cutter is available in different designs, depending upon operation. Use the three-cartridge design for reliable performance in under-coolant applications.

Read more

 

B681 – Stable and productive roughing cylinder boring

B681 is designed and developed for roughing in cylinder boring operations. The solution produces excellent roundness and cylindricity, allowing for a smooth semi-finishing operation due to the integrated Silent Tools™ damped adapters.

More about B681 roughing cylinder boring

B681 roughing cylinder boring 

B683 - stable and productive semi-finishing cylinder boring

B683 is designed and developed for semi-finishing in cylinder boring operations. The solution produces excellent roundness and cylindricity, allowing for a smooth finishing operation due to the integrated Silent Tools™ damped adapters.

More about B683 semi-finishing cylinder boring

B683 semi finishing cylinder boring 

* For engineered tooling solutions, please contact your local Sandvik Coromant sales representative.

 
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