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      Technical Development

      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;


      3、Milling 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;


      4、Pipe 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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