毛化刀具

Cylinder roughing tool simplifies the pre-machining of surface汽缸孔毛化刀具简化表面预加工流程Premium quality for passenger car engines用于高品质的乘用车发动机的加工Coated cylinder bores are the current trend in engine construction, because they improve the life cycle assessment of a passenger car. For high-quality coatings, an optimally prepared surface is essential. Amongst other things, special roughing tools are used. Walter AG in Tübingen uses a single edge boring bar concept with PCD inserts. 涂层式汽缸孔是当前发动机构造的趋势，引起它们能改善乘用车的寿命周期评估。

对于优质涂层而言，确保最佳的表面制备是关键所在。

而其核心加工工艺是特制的毛化刀具的使用。

总部位于德国图宾根的瓦尔特公司使用装有单刃PCD 刀片镗杆的理念。

Automotive manufacturers are trying all kinds of adjustments and refinements so that cars can become even more environmentally friendly. As part of this, they also have their sights set on the engine block. Grey cast iron is being replaced with light metal casting. Less weight consumes less fuel, and thus generates less CO 2. But due to its sliding qualities, grey cast iron bushes are still used in aluminium engine blocks. Maybe still – but not for long. This tried and tested material, even in this form, is on its way out. It is increasingly being replaced with coatings. A grey cast iron bushing has a wall thickness of 3 to 4 mm, but a coating measures just a tenth of that. In a four cylinder vehicle, an engine soon becomes narrower by 25 to 30 millimetres thanks to coating technology. But this space saving is just one aspect. Modern coatings also provide better wear behaviour. This means less oil enters the combustion chamber, and harmful emissions are further reduced.汽车制造厂正在进行各种调整和细化，让汽车变得越来越环保。

作为优化的，他们还把重点放在发动机缸体上。

灰口铸铁正在被轻金属铸件取代。

发动机轻量化，降低燃油消耗，减少二氧化碳排放，但是由于缸孔-活塞环摩擦副的质量要求，灰口铸铁衬套仍用于铝制发动机缸体中，但时间不会太长。

就是这种久经证明的材料也不得不另找出路。

它正在被涂层取代。

灰口铸铁衬套壁厚为3～4毫米，但涂层厚度只有它的十分之一。

由于采用涂层技术，车用四缸发动机不久变窄25～30毫米。

这种节省空间只是一个方面。

这种新型的涂层有更好的耐磨性能。

也就是说，进入燃烧室的润滑油将减少，从而减少有害气体的排放。

A high-quality coating requires careful pre-treatment of the basic material. This applies above all to highly stressed cylinder bores. The classic pre-treatment methods are water or corundum blasting. Under high pressure, the pre-drilled cylinder surface is coated with a lunar landscape, providing a corresponding surface of adhesion for the coating metal. But blasting techniques have some disadvantages: The systems are cost-intensive, they require space, and the costs for internal logistics increase. In addition, water or corundum are deemed a problem substances in production. Corundum, for example, demands intensive subsequent cleaning of the parts. The alternative lies in mechanical machining of the surfaces with a counter-boring or roughing tool developed specifically for this purpose. With this method, the crankcase can remain on the machining centre on which the cylinders were previously bored. The use of the special tool is just one additional machining process among many and can therefore be easily integrated in a production line. A significant simplification.优质涂层要求必须对基材进行细致的预处理。

这主要用于承受大应力的汽缸内壁。

传统的预处理方法是喷水或喷砂处理。

在高压条件下，预加工的汽缸表面被涂成月白色（lunar landscape），以此为涂层金属提供良好的附着表面。

但是，喷砂技术也存在着一定的缺陷：系统属于成本密集型系统，要求的空间大，内部物流成本较高。

另外，在生产中水和金刚砂是被认为有问题的介质。

例如，金刚砂要求后续大量的零件清洁工作。

所以可替换的方案因此而生：使用成型的孔加工刀具或粗加工刀具进行机械加工。

如果采用这种方法，曲轴箱就可以保留在前序粗镗汽缸孔的加工中心上了。

使用这把非标刀具只是在众多工艺中的一道附加加工工艺，并且可轻松融入生产线中，工艺大大简化。

Several approaches are feasible for this type of special tool. “We rely on a stable, single edge boring bar,” explained Burkhard Krauß, Automotive Component Manager at Walter AG in Tübingen and responsible for crankcase machining. "Single-edge means that it is equipped with just one cutting insert. This is made of PCD and is very delicate. It has many small individual edges, which create a profile with indentations on the cylinder surface." Just like a thread, the tool cuts a dovetail-like profile groove through the entire crankcase. The width of the groove ranges from 120 to 180 µm, the depth from 60 to 130 µm. The indentations are important, as they enable the coating metal to interlock with them. “T he various coating procedures commonly used today – such as APS, PTWA and LDS methods –require different profiles or cutting inserts,” said Burkhard Krauß. Walter provides all variants. Thanks to many years of PCD expertise, Walter is even able to supply customised solutions quickly.这类非标刀具可使用多种切实可行的方法。

图宾根瓦尔特汽车零件经理兼曲轴箱加工负责人Burkhard Krauß说，他们依靠可靠的单刃镗杆，单刃指的是镗杆只配有一个切削刀片。

采用PCD材质，很精密，有很多独立切削刃口，可加工成汽缸表面上带凹槽的轮廓。