Productive aluminium machining for automotive powertrains

Milling solutions

Sandvik Coromant offers a well-rounded selection of milling cutters for aluminium automotive components.
M5Q90 is the cubing specialist of the M5 family of milling concepts, in other words it is designed for the first roughing stage to clean the surfaces of newly cast parts. These shoulder cutter with indexable inserts have cutting edges only on the radial periphery of the tool body. The tangential PCD inserts generate smooth cutting action that enables low power consumption and minimal vibrations. The tool performs reliably and provides a long tool life. These characteristics make it the first choice for cubing cylinder heads, engine blocks and similar components. M5Q90 cutters are always tailored to the customer’s application.

M5R90 is a roughing and semi-finishing concept for shoulder milling operations, with cutter diameters ranging between 63 and 250 mm (2.48–84 inch). The tool has re-grindable PCD tips brazed to a steel cartridge, which allows axial adjustments and consequently large depths of cut, up to 8 mm (0.315 inch). Two radius options, 0.4 mm and 0.8 mm (0.016 / 0.031 inch), are available, depending on the cartridge model. M5R90 is a reliable, easy-to-use cutter that can be optimally teamed up with M5B90 when excellent surface finishes are required (below 4Rz).

The M5C90 concept is based on M5B90 and likewise offers smooth cutting action free of burr, scratches and breakages with indexable inserts in a stepped configuration. What sets the M5C90 face mills apart, is their extra row of roughing inserts positioned tangentially on the outer diameter. They are designed to accomplish both roughing and finishing cost-effectively in a single operation. Typical components are the same as with M5B90: cylinder heads, blocks, covers, and other aluminium components with wide material engagements. M5C90 cutters are always tailored to the customer’s application.

The M5B90 face milling concept offers a highly effective tool for super finishing cylinder heads, blocks, covers, and other aluminium components with wide cutting engagements. Fitted with indexable inserts, it offers unique cutting action not unlike broaching: the inserts are positioned in a progressing radial and axial sequence where each insert cuts slightly deeper than the previous one. This allows minimal stock removal for each individual insert and consequently burr-free cutting milling. Using only one wiper insert in the last position gives an outstanding surface finish. The limited material removal rates per insert also extend the tool life. M5B90 cutters are always tailored to the customer’s application.

M5F90 is a dedicated face milling cutter for machining thin-walled aluminum components in a single operation but it can also be used for spot facing and operations with wide material engagements. The cutter is based on a stepped concept similar to M5B90 and M5C90. The combination of a cutter body (diameter 25–80 mm/0.98–3.15 inch) and brazed PCD tips enables high feed rates with minimal vibration tendencies. Each insert has a roughing edge, on its periphery, and a finishing edge, on the cutter face. Thanks to this, the component can be finished in a single operation with excellent surface finish. Typical components include gearbox casings, housings, and other thin-walled parts.

ISO N round solid tools

Auto components are typically mass produced parts with high density of complex hole geometries – an application that often justifies the use of optimized drilling tools to achieve maximum productivity and long tool life for high productivity, and ultimately, low cost per hole.

CoroDrill® 400 is a straight flute drill designed for complex multi-step, chamfer and radius forms as well as large step ratios over diameters ranging between 3 and 25 mm (0.118–0.984 inch). The hole depth can be up to eight times the drill diameter. These drills excel in easy chip removal, hole straightness and surface finish. The drill family offers both solid carbide and PCD options, including the veined PCD solution for power feed machines and metal stacks.
CoroDrill® 430 is a 3-flute spiral solid carbide drill for core drilling, in other words opening out existing holes. The diameter and hole depth ranges are the same as for CoroDrill® 400. These are rugged drills for smooth entries and exits through uneven surfaces without burr formation or flaking. CoroDrill® 430 offers excellent hole size control and straightness in challenging conditions.

Thread forming is the favoured threading solution for aluminium engine components and the CoroTap® 400 selection of chip-free forming taps is the first choice for this application. The product family includes versatile, optimized and customized solutions both for through and blind holes as well as for most thread forms and standards.

Aluminium in powertrain components

The power train of a European passenger car typically contains around 80 kilograms of aluminium, which means these components – the engine, gear box, suspension parts, housings – are an obvious area of interest for light weighting measures.

In terms of weight reduction, the engine block and its accessories, such as intake manifold, water pump etc., is the single most important group of automotive components, as it accounts for 3–4% of the total weight of an average vehicle. By replacing the conventional cast iron with aluminium alloys can reduce the weight of the engine block by up to 40–55%, even accounting for the lower strength of aluminium compared to grey cast iron.
Several transmission components, particularly gear box housings, electrification devices/components, suspension arms and rear axle, are prime examples of driveline applications where aluminium is a favored material.