Application Solution of Auto Indutry

• Auto parts are an indispensable part of the whole car, and the car is the foundation of industrial development. The quality of auto parts directly determines the quality of the whole vehicle. This year, the global auto parts industry will begin to enter a stage of rapid development, aiming at the production of auto parts. The chain also continues to rise. In the production process of auto parts (brake pads, brake drums, engine cylinders, clutches, gears, bearings, etc.), the insert is an important cutting tool besides the material, which determines the tolerance and assembly accuracy. The commonly used materials are gray cast iron, quenched For steel, aluminum and other materials, SCBN TOOLS has developed a variety of material CBN inserts, and different tool materials are used for different parts. The specific materials are as follows:

  
  

Common Insert Pictures:

• Processing Cases

Brake Disc Processing Case

• The performance of the brake disc is a strong guarantee for the safe driving of the car. As the core component of the auto parts, the brake disc is the most important safety part. The commonly used materials for brake discs are HT250 and HT200. The brake disc determines the quality of the car's braking effect. The processing technology of the brake disc has higher requirements on the finish and processing efficiency. The manufacturing process of auto parts is constantly updated, and higher requirements are also put forward in terms of accuracy, efficiency, and life of tools used when machining brake discs. SCBN TOOLS launched SBN850 and SBN900 special tools for turning of brake discs, using a single tool to improve production efficiency. 

  
  

  

• Processing condition: rough turning, semi-finishing turning
  

  Cutting parameters: ap=2.5mm, Fr=0.2mm/r, Vc=1100m/min

  Cutting method: dry cutting

  CBN tools made of SBN850 achieve customer satisfaction, with a 180% increase in service life and a 200% increase in efficiency.

Gear Processing Cases

• Gears are an important part of automobile transmission. The product strength, precision and fatigue life of gears have high requirements. Therefore, there are high requirements for gear materials, and at the same time, the requirements for tools are also increased. Common gear materials are: 20CrMnTi, GCr15, 42CrMo, Etc. SBCN TOOLS has developed SBH150 and SBH170 materials for gear processing, which are respectively used for the processing of gear end face, outer circle, inner hole and tooth tip.

  
  

  
  

• Continuous Finishing Gear-Inner Hole-SBH170

  Processing Position: inner hole of gear

  Workpiece material: 20CrMnTi, HRC58~62

  Processing condition: continuous cutting

  Selected tool: SBH170 CNGA120404

  Cutting parameters: Vc=180m/min, ap=0.15mm, Fr=0.1mm/r

  Advantages: Tool life is 4 times longer than ceramic tools for finishing gears, and the production cycle time is only 40% of ceramic tools.

  
  

• Slightly interrupted finishing gear-bore-SBH130

  Processing Position: gear inner hole (with keyway)

  Workpiece material: 42CrMo,HRC60

  Selected tool: SBH130 CCGW09T304

  Cutting parameters: Vc=120m/min, ap=0.1mm, Fr=0.05mm/r

  Advantages: Tool life is 8 times that of carbide tools for finishing gears, and the production cycle time is only 30% of alloy tools.

• Heavy Interrupted Finishing Gear-End Face-SBH190

  Workpiece name: Gear (with group holes on the end face)

  Workpiece material: SCM420H, HRC45-48

  Machining process: strong intermittent turning gear end face

  Selected tool: SBH190 CNGA120408

  Cutting parameters: Vc=100m/min, ap=0.25mm, Fr=0.05mm/r

  Advantages: The tool life is twice that of other CBN tools for finishing gears, and it does not break down in intermittent machining conditions, and ultimately normal wear.

Bearing processing case:

• The main function of the bearing is to support the mechanical rotating body to reduce the friction coefficient of the mechanical load during the transmission process of the equipment. Bearings are components that fix and reduce the friction coefficient of the load in the process of automobile transmission. It is an important component that determines the stability of automobile transmission and noise. It must have high hardness and wear resistance requirements. It is a big challenge for machining tools. The use of  tools grades SBH150 and SBH170 of SBCN TOOLS can effectively ensure machining accuracy and smoothness.

  
  

• Processing GCr15-Metallurgical Bearing-SBH150

  Workpiece name: metallurgical bearing

  Workpiece material: GCr15, HRC55-58

  Selected tool: SBH150 DNGA150408

  Cutting parameters: Vc=140m/min, ap=0.3mm, Fr=0.15mm/r

  Advantages: Using SBH150 CBN inserts to process metallurgical bearings is 3 times more efficient than ceramic tools, and at the same time has more cutting edges, which is more economical and reduces the tool cost of a single workpiece.

Engine block Processing Case

• Case of Milling Gray Cast Iron Gearbox Housing

  Machine tool: American horizontal machining center

  Tool grade: SCBN Tools solid CBN insert with grade SBN900

  Linear speed: 900-1200m/min，Fz: 0.05-0.1mm/z;

  Cutting depth: finish milling 0.5mm, semi-finish milling 1.5mm.

  Approved life: The line speed is 900-1200m/min, and the life of the solid CBN insert SBN900 is 110-160 minutes (single edge); the approved life can be extended during semi-finish milling, and the number of processed workpieces is at least 420 pieces. Due to the use of non-metallic binders, CBN tool life is longer than commonly used CBN inserts.

• Finish-milling engine block:

  Processing parts: engine block

  Processing operation: finish milling

  Insert model: SBN900 SNEN090304

  Cutting parameters: Vc=1500mm/min, Fz=0.12mm/z, ap=0.3mm

  Processing method: dry cutting

  Machining effect: SBN900 grade milling gray cast iron engine block can obtain high surface finish and ensure tool life at the same time.