**Abstract**
Engine technology is at the heart of developing more efficient and environmentally friendly vehicles. The performance of an engine depends on a variety of factors, including the use of new materials and advanced designs, the quality of components, and the precision of manufacturing processes. In today’s highly competitive automotive industry, cost-effectiveness plays a crucial role in maintaining a strong market position. One of the key steps in improving efficiency is machining the engine block more effectively, which directly impacts both the cost and time required for each part.
In engine construction, achieving the right workpiece structure, ensuring a smooth surface finish, and avoiding scratches are essential to guaranteeing overall quality. To meet the growing demands for cost-effective production, reliable and efficient tools are necessary, especially for roughing and finishing operations on critical parts like cylinder blocks and cylinder heads. The upper end face of the cylinder block is one such area that requires precision and consistency.
Roughing is typically the first stage in the machining process, often performed at casting suppliers. At this stage, the primary goal is to maximize metal removal rates. On the other hand, finishing demands high efficiency, reliability, and superior quality. A particularly challenging operation is face milling of the combustion surface, which is usually the final step in completing the geometry of the cylinder block.
Cast iron remains the most widely used material in engine manufacturing, with gray cast iron being the dominant type. However, other forms such as compacted graphite iron (CGI), austenitic malleable cast iron (ADI), and various alloy cast irons are gaining popularity due to their improved properties. Additionally, bimetallic machining—combining a cast iron lining with an aluminum cylinder block—is becoming more common.
Recently, Fenix has introduced advanced cast iron milling solutions that significantly boost productivity and reliability. The Fenix automotive milling cutter stands out as a leading tool in this field. As the demand for small-cutting parts increases, more machining centers are now handling these tasks. In production lines or standalone machines, over 80% of tool diameters fall within the range of 63 to 160 mm, indicating a shift from heavy-duty machining toward smaller, more precise operations.
For the development of heavy-duty milling applications, key targets include table feed speed, cutting forces, workpiece integrity, burr formation, surface quality, and noise levels. These challenges require innovative and robust solutions.
To address the specific difficulties of engine block milling, Fenix has developed PCBN (Polycrystalline Cubic Boron Nitride) milling cutters that offer significant advantages over traditional coated carbide and ceramic tools. Compared to imported PCBN tools, Fenix’s solution provides better cost-performance while maintaining or even improving surface quality. During roughing (ap=2.5mm) and finishing (ap=0.5mm) of the engine block’s front and rear faces, the feed speed can reach up to 3670m/min, increasing the production cycle by 30 seconds per piece and extending blade life to 140 pieces per edge.
When machining the top and bottom of the cylinder, the Fenix PCBN milling cutter improves processing efficiency by 1.5–2 times and extends blade life by 2–3 times. For finishing the cylinder head surfaces, the feed speed of the Fenix PCBN insert is 1.2 times faster than that of European PCBN inserts, offering three times better cost-performance.
In China, the automotive parts industry, particularly in engine manufacturing, has vast growth potential. However, competition is intensifying, and manufacturers must find ways to enhance production efficiency, product quality, and reduce costs. Fenix leverages its more than 20 years of experience in the CBN industry to develop innovative tools and solutions tailored for engine and automotive parts. By doing so, it helps Chinese manufacturers improve productivity, profitability, and long-term competitiveness.
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