Meeting Stringent Requirements
Application
Large automotive engine block made from high-silicon aluminum
Material
High Silicon content aluminum
Tool
A special extra-long (14” OAL) Carbide Series tool with a rear cutting only inserts
The Challenge
To deburr the series of internal ribs in a very long aluminum engine block.
The speed & feed is 1250 RPM @ 400 mm/min.; cycle time 12-15 seconds.
We had to make an extra length tool that could handle these cutting conditions without adding any cycle time to the process. The insert had to produce a clean, smooth surface and run a consistent number of blocks each and every shift.
The Solution
The initial testing resulted in a built up cutting edge on the inserts. Our solution involved working closely with our coating vendor to apply the perfect coating to the inserts to get the desired results.
The Results
The tool design, cycle time and performance all met the stringent requirements as specified by our customer. We made sure to always have a batch of these specially coated inserts ready for release, and enough long reach arbors to have ready to deliver in less than 2 weeks.