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ZCC.CT tools Application in Exhaust Manifolds Machining

Date:2020/04/15


Exhaust manifolds is the part of an engine that supplies the air to the cylinders. The function is to collect engine exhaust from multiple cylinders and deliver it to a treatment system so as to avoid environmental detriment. Exhaust manifolds are generally made from cast iron or nodular cast iron materials. In recent years, due to light weight, durability and smooth inner wall and low exhaust resistance, it have been applied in automotive industry more and more massively.

Here is the solution for exhaust manifolds machining

Workpiece Material: Nodular Cast Iron HB200

Technical Process

■Milling face of large flange

■Hole making for large flange

■Milling and hole-making for flange face of supercharger

■Pipe orifice machining



1Milling face of large flange




Cutter body:FME03-125-B40-SP12-08

Rough milling  

insert:YD201/SPKN1203EDTKN

cutting data: V=100m/min , fz=0.15~0.24mm/z ,ap=3~4mm;




Finish milling

Insert:YD201/SPKN1203EDFR,

YD201/SPEX1203EDR-1(with wiper)。

Cutting data:V=100m/min , fz=0.1mm/z,ap=0.5mm。



2Hole making for large flange

There are three main dimension, they areΦ13.1X6 (hole number), Φ11X1 (it is a elliptical hole and drilling first then milling)


Drilling:

Tool:1105SC03-1310,1105SC03-1100

Cutting data:n=1400~1600r/min , fr=0.2~0.3mm/r;

Elliptical hole Milling

Tool:PM-2E-D6.0

Cutting data:n=7000r/min , fz=0.04mm/z;


3Milling and hole-making for flange face of supercharger


Flange face: Requiring sharp cutting edge and low cutting force

Tool:FMA04-125-B40-OF05-08

insert:OFKT05T3-DF/YBG102

Cutting dataCutting data:V=210m/min,fz=0.2mm/z

Drilling on small flange:

Tool  1105SC03-1050

Cutting data:n=1400~1600r/min , fr=0.2~0.3mm/r;


4Pipe orifice machining


Face Milling

Tool:FMD02-080-B32-PN11-10

Insert:YBD152/PNEG110512R-CM

Cutting data:V=100m/min , fz=0.15mm/z ,ap=2mm;


Rough Boring

Tool: Rough boring tool with two

doublecutting edges

Insert:YBD151/CCMT09T304-HM

Cutting data:V=150m/min,fz=0.2mm/z

Finish Boring:

Tool: Innovative precision boring tool

Insert:YNG151/TBGH060102L

Cutting data:V=180m/min,fz=0.1mm/z





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