Brake drum is usually made from gray cast iron. The coating carbide tools or ceramic tools can only process 20-50 pieces brake drum, and it needs to interrupt production to change new tools, it wastes lots of time.

But now, More Super Hard has an indexable PCBN inserts which uses metal bond agent, with super high hardness and wear resistance. Each edge can process 70-100 pieces brake drum, it improves the production efficiency a lot, it is an ideal choice for cast iron cutting.

The transmission housing is one of the most important parts of the car, assembling parts such as shafts, sets and gears to keep them in the right position altogether. Therefore, the assembly accuracy of these parts box components and the performance and life of the installed machine are largely determined by the processing quality of the box itself.

Transmission materials are often used for gray cast iron, can also be used cast steel parts. For cast iron transmission housing blank machining with slag and pores, traditional processing methods are difficult to meet the processing requirements of the transmission housing, More Super Hard introduced a multi-cutting edge PCBN blade (multi-tooth milling disc) for easy loading and unloading, a blade can be processed 70-100 pieces, After the edge is worn, another edge can be replaced, improving the processing efficiency by 50-70%.

Our PCBN cutting tools are utilized in many areas of automotive component production, particularly in the finish machining of hardened steel, such as in the ‘hard-turning’ of gears and transmission shafts and in the machining of grey cast iron brake discs.

For example, one PCBN cutting edge can machine up to 10,000 brake discs compared to a ceramic tool cutting edge which can only machine several hundred brake discs.

For Cylinder block

Our CBN cutting tools are used in applications such as cam and crank shaft grinding, and the rough and finish grinding of steel gears.

Our PCD cutting tools are used across the automotive production process, from alloy wheel, cylinder block, cam and crank shaft casing machining, to milled, bored and reamed gearbox housings.

In addition, PCD cutting tool is the only viable solution for the finishing of new generation ceramic metal matrix composite brake discs.

 Study Case

The car engine is a machine that provides power to the car, and is the heart of the car, affecting the power, economy and environmental protection of the car. In the machining of engine box parts, positioning and clamping of engine blocks, cylinder heads and other parts, the choice of tools and processes are very important. There are now many tool manufacturers in China in this regard. New breakthroughs and innovations.

The box body is an important part of the five major parts of the engine, and the processing accuracy is high, and the process is complex is the main feature in the processing process.

The box body blank parts are generally made by casting, and the general material is gray iron 250.

In order to improve the performance of the engine, the piston material is changed from low silicon aluminum alloy to medium silicon aluminum alloy, and even high silicon aluminum alloy.And the PCD tools with excellent characteristics, it widely used in processing aluminum alloy, especially for high silicon aluminum alloy.

The hardness and wear resistance of high silicon aluminum alloy are higher than other aluminum alloys. When normal cutting tools alternately cut soft aluminum and hard silicon particles, the tool is also easy to produce debris, so the processing accuracy and surface roughness will deteriorate.

In order to avoid chip deposition and hardening, the blade must be sharp and the blade surface must be smooth, and the PCD cutter meets these requirements.

Gearbox housing is the basic parts of transmission. Its main function is to support each transmission shaft, to ensure the center distance and parallelism between each shaft, and to ensure the correct installation of the gearbox housing parts and the other parts which connected to them. It also affects the working accuracy and service life of the car, so the quality of the gearbox housing should be very good. It is particularly important to use the proper and superior tools.

PCD tool has good cutting performance and chip breaking and chip removal, it can obtain high dimensional accuracy and surface roughness. At present, die-cast aluminum gearbox housing is one of the mainstream materials, and PCD tools are recommended to process this kind of material.

For the typical holes such as tappet holes, spark plug holes and fuel injection nozzle holes, how to improve the processing efficiency and ensure the coaxiality of each hole, More Super Hard used a multi-step machine to process composite tools, multi-stage hole centralized processing, and dilute different processing Process limits, reduce the number of tool changes, save tool change time, and reduce tool inventory. Coupled with the high precision and wear resistance of PCD, from process optimization to efficient and stable processing, it perfectly solves the processing problem of difficult-to-machine holes.

Mill cutter for cylinder block cross section