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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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