MAPAL High-performance precision tooling for automotive machining

Faced with the ever-increasing demand for cutting tool products from modern manufacturing processes, MAPAL is working hard to provide customers with high-precision, long-life tooling products, saving customer costs.

As a tool supplier in the special Precision Machining industry, MAPAL's tool products are mainly used for the machining of holes, special holes and special parts of workpieces, and are particularly suitable for the mass production of Precision Parts.

At present, in the field of automobile and generator manufacturing, Mapar's cutters are widely used. The following are the products used by Mapa in the automotive and generator manufacturing and manufacturing fields:

Automotive engine field

1. Production of cylinder head

In the manufacture and manufacture of automobile engine cylinder heads, the key processing technology is to ensure the sealing of valve guide tubes and seat rings (required surface roughness Ra0.8mm, face runout error 0.01~0.03mm), and surface processing.

(1) Surface processing. MAPAL's WWS milling cutter (see Figure 1) is used to machine aluminum alloy cylinder heads, which can achieve a maximum linear velocity of νc = 7 660 m/min and a maximum depth of resection up to 6 mm.

(2) Process conduit and seat bottom hole. Figure 2 shows the PCD precision step boring tool provided by MAPAL, which can effectively ensure the workpiece concentricity requirements.

PCD precision step trowel

(3) Processing catheter and seat hole. In this process, the guide knives should be used first, and then the tape guide knives should be used for processing. When the concentricity of the valve guide and the valve seat is less than 10mm, an open tool (see Fig. 3) can be used to ensure the machining accuracy. The tool is a centrifugal sliding type unwrapping knife. It uses the centrifugal force as a power to process the hole of the guide tube. This can control the feed rate of the tool by changing the rotation speed of the machine tool spindle, and can achieve high processing accuracy (concentricity can be achieved. 7~8mm). Of course, if the “feed out” system is used on the special plane to carry out the hole of the car or the sill ring, the knife that processes the hole of the catheter is sent out from the center, and high concentricity can also be achieved.

Expanding tool

2. Production of cylinders

Special composite trowel

In the machining of cylinder bores on the cylinder block, MAPAL provides a special tool (see Figure 4). The tool is basically the same in the machining center and on the special plane, through the implementation of rough, semi-finishing and finishing processes. Composite, can achieve νc = 100 ~ 120m/min (using carbide blades), νc = 400 ~ 700m/min (using CBN blades), processing surface roughness up to Ra (1.0 ~ 2.0) mm, cylindricity 2~5mm.

3. Processing of camshaft holes

As an important part of the engine, the machining accuracy of the camshaft hole is very high. At the same time, the machining time is relatively long. Sometimes it is necessary to process the bearing end face and the cutting groove at the same time. Therefore, the machining is difficult.

The usual processing method is to use a wire boring tool for processing on the special machine. MAPAL can provide high-quality and inexpensive wire boring tools without special equipment for machining the bearing end face. However, due to the complexity of the wire boring tool, the machining accuracy is not high. Therefore, if high-volume production conditions and poor CPK are required, MAPAL recommends using a tool with a guide bar (see the figure below).

Tool with guide bar

Hydraulic parts processing applications

MAPAL's tool products can also be used to process a variety of hydraulic products, such as steering gear master cylinders, water pumps, and automotive accessory valves. Its main advantages are high machining accuracy, dimensional stability and long tool life, making it ideal for mass production.

Conclusion

MAPAL is constantly growing and expanding its product coverage area, and is committed to providing customers with a full range of services to help customers improve production efficiency and reduce production costs. More than 95% of MAPAL's tool products are special special tools that can meet the customer's special requirements.