Seat and guide parent metal

Valve parent metal finishing

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.

Kyocera 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/min. to Vf 8,000 mm/min., 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
• 8,000 mm/min. feed rate
  Counterbore: 2,500 mm/min. feed rate
• Tool life 300,000 holes
• Tool costs = 0.01 euro/cylinder head

Machining centre

• 50 bar internal coolant
• 9% emulsion
• Material : ALSi10MgCu

PCD step/profile reamer

Features

Combining reamer and profile geometry on the PCD inserts, this multi-purpose PCD tool is able to cut three different difficult features in one PCD tool.

Fluting and cutting geometries developed specifically for this application.

Benefit

This combination reamer enables reduced overall cycle time due to fewer operations and increased cutting parameters.

Cutting data example

n = 8000-15000 RPM, fn = 0.3-0.5 mm/rev.