Auto Parts

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Halnn tools can process many Auto parts.jpg


In the process of processing auto parts, the tool often has problems such as wear resistance, low efficiency or high hardness of the parts, and the processing does not move. For these reasons, Halnn has developed a variety of grades to deal with different materials of auto parts. The specific cutting parameters are as follows

Processing materials

Processing type

Recommended CBN cutting parameters

Recommended CBN grade

Cutting speed Vc(m/min)

Cutting Depth ap(mm)

Feed Rate Fr(mm/r)

Hardened Steel (hardness ≥HRC45)

Finishing

90-250

≤1

0.05-0.35

BN-H05, BN-H10, BN-H11, BN-H21, BN-H20

Grey cast iron

Roughing

400-1200

1-10

0.2-1.0

BN-S300

Finishing

600-2000

≤1

0.05-0.3

BNK30

Powder metallurgy

Roughing

80-150

≥0.5

0.1-0.5

BNK30, BN-K10, BN-K50, BN-H21

Finishing

90-180

≤0.5

0.1-0.2


Workpiece material

Recommended PCD cutting parameters

Recommended PCD grade

Cutting speed Vc(m/min)

Cutting Depth ap(mm)

Feed Rate Fr(mm/r)

Aluminum alloy

4-8%Si

100-5000

0.03-0.5

0.1-3.0

CDW010

CDW302

CDW005

CDW850 (CDW20-1)

9-13%Si

100-3000

0.03-0.5

0.1-3.0

CDW010

CDW302


CDW850 (CDW20-1)

>13%Si

100-2500

0.03-0.4

0.1-2.5

CDW010

CDW302

CDW025

CDW850 (CDW20-1)



Tools for Auto Parts Machining

CBN PCD inserts

Milling Drilling Reaming

Ball cage milling cutter

Milling cutter tool holder

 

Brake Discs/Drums

Brake discs and drums

Brake discs/drums, as typical mass-produced Auto parts, mainly material is gray cast iron. And large enterprises mostly use special machines or automatic production lines for brake discs and brake drums for production, which have high performance requirements for machine tools and cutting tools. While ensuring the quality, the company pays more and more attention to the improvement of efficiency. For this, Halnn which can better meet the requirements of high-speed machining of brake discs and brake drums, Halnn CBN tool life and stability are 50% or even several times higher than that some brand CBN inserts.


BNK30, a new CBN grade developed by Halnn tools, adopts the optimal ratio of nano-scale binder and high-purity CBN particles. 


Recommended inserts and grades


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CNMN/CNGN

SNMN/SNGN

SCGN

WNGA

TNGA

CNGA


Roughing Brake discs and Brake drums: Insert grade: BN-S300, Insert types CNMN/SNMN

Finishing Brake discs and Brake drums: Insert grade BNK30, Insert types SCGN/CNGA/WNGA/TNGA/VNGA, etc.

High-speed cutting at cutting speed of 500-2000m/min, to meet the stable cutting of brake disc and brake drum parts, especially finishing, the performance advantage is more obvious.

At the same time, Halnn tools can also customize inserts such as wipers and coatings according to customer needs to help high-speed cutting of brake discs and brake drums.


Application cases

 

Workpiece: Brake Disc

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Material: GC250 (HT250), Hardness: HB210

Insert Type: BN-S300 CNMX120716(Positioning hole)

Cutting parameters: Vc=800m/min, Fr=0.45mm/r, ap=2mm

Processing method: Semi-finishing, Dry Cutting

Insert grade

Cutting Speed

Efficiency

Halnn BN-S300

800m/min

Improved 6 times

ceramic inserts

800m/min

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Engine block

Halnn CBN inserts milling Engine block.png

Milling process: Halnn CBN insert BN-S300 is used, which has significantly improved productivity and stable cutting performance, which can advantageously replace international first-line brands such as Seco tools.

Boring process: BN-S300 grade or BNK30 grade is recommended, which has high cost performance and stable cutting performance, and is one of the representative works of localization of tools in the engine industry.

Cylinder port chamfering process: Customized according to customer needs, the advantages are stable cutting performance and high cost performance.

For the aluminum alloy engine block: Halnn PCD tools are selected for high-speed milling flat, the cutting speed can reach 3000m/min, and it has excellent processing characteristics. For the hole system, Halnn PCD reamers are recommended to improve tool life and ensure high dimensional accuracy and surface roughness.


BN-S300 CBN inserts SNEN090308 milling Engine Block

Workpiece: Engine Block

Material: FC250(HB170~210)

Insert Type: BN-S300 SNEN090308

Cutting parameters: Vc=1700 m/min, Ap=0.3mm, Fz =0.12mm/r

Processing method: dry cutting(Finish milling)

Insert grade

Feed Rate

Tool Life/edge

Efficiency

Halnn BN-S300

3670mm/min

100 pieces

Improved 0.6 times

Some brand CBN

2200mm/min

80 pieces

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Engine cylinder head

Halnn CBN inserts milling Engine cylinder head.png

Finish milling cylinder head: BN-S300 grade Solid CBN insert is recommended, the productivity is significantly improved and the cutting performance is stable. It can advantageously replace international first-line brands such as Seco Tools.

Valve chamfering: customized according to customer needs, the advantages are stable cutting performance and high cost performance.

Turning valve seat ring: DCGW11T304 etc. is recommended for commonly types. The advantage is that high-speed cutting can be achieved and a higher finish can be obtained.


Boron cast iron cylinder liner

Halnn CBN inserts turning Boron cast iron cylinder liner.png

Cylindrical turning: BN-S300 grade of Solid CBN insert is recommended, which can be dry-cut, and its tool durability is N times higher than that of ceramic tools.

Grooving: customized according to customer requirements to obtain longer tool life and higher production efficiency.


Finish turning Cylindrical

Workpiece: Finish turning Cylindrical

Material: Boron cast iron

Insert Type: BN-S300 SNMN120412

Cutting parameters: Vc=850 m/min, Ap=0.5mm, Fz =0.25mm/r

Processing method: Wet cutting

Insert grade

Cutting speed

Machining beat

Tool Life/edge

Halnn BN-S300

850m/min

23 s/piece

120 pcs

Ceramic inserts

500m/min

40 s/piece

25 pcs



Gear, Gear shaft

Halnn CBN inserts turning Gear, Gear shaft.png



Recommend Grade and Process conditions

BN-H05 and BN-H11 grades for continuous process, with can high-speed cutting

BN-H10 and BN-H20 grades for Light interrupted cutting conditions, can withstand the impact of the keyway during hard turning, with stable performance

BN-H21 grade of PCBN insert is recommended for heavy interrupted cutting conditions, with good toughness, impact resistance and stable performance

Cases of Hardened Steel Gear Process

Workpiece: Gears, Inner hole,Light interrupted

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Materials20CrMnTi

Hardness: HRC58-62

TypeBN-H10 CCGW09T304

Cutting ParameterVc=135m/minFr=0.08mm/rap=0.25mm

Cutting condition: Dry Cutting

Tools Life

Efficiency

Inserts

1000 Pcs

Improve 22%

Halnn CBN BN-H10 Grade

600 Pcs

----

Other CBN Grade

 

Gearbox housing

Halnn CBN inserts turning Gearbox housing.png

Milling process: The BN-S300 grade for Solid CBN insert is recommended, which significantly improves the production efficiency of the coated carbide tool and increases the tool life by N times.

Boring process: PCBN inserts (including composite and brazed) are recommended, which can significantly improve production efficiency and achieve higher surface quality.

For aluminum alloy gearbox housing: Halnn tools can provide PCD milling, boring, reaming, drilling and other tools, which greatly improves production efficiency, ensures high dimensional accuracy and reduces production costs.


Pulley

The material is HT250, which is mainly used for end face machining. PCBN inserts (including composite and brazed types) are recommended. The advantages are: stable cutting performance and doubled production efficiency.

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Cv Joint

Process: Hard turning process after hot, recommended PCBN inserts, cost-effective, stable cutting performance, and can intermittent machining.


Halnn CBN inserts turning Cv Joint.jpg

Workpiece: CV joint (finish)

Material: Hardened Steel

Insert Type: BN-H10 TNGA160408

Cutting parameters: Vc=190m/min, Fr=0.15mm/r, ap=0.15mm

Processing method: Dry cutting

Insert grade

Cutting speed

Tool Life/edge

Tool cost

Halnn BN-H10

190m/min

355 pcs

0.06 RMB/pc

Other CBN inserts

170m/min

370 pcs

0.1 RMB/pc


Synchronized pulley

The material is powder metallurgy. Due to the porous structure, the cutting edge of the cutting tool wears sharply. At this time, Halnn tools PCBN insert is recommended, the advantages are: sharp inserts, stable cutting performance, and tool life is increased by 50% compared to other brands CBN tools.


Halnn CBN inserts turning Synchronized pulley.jpg

Workpiece: Synchronized pulley(Finishing)

Material: Powder metallurgy

Insert Type: BN-K50 DCGW11T304

Cutting parameters: Vc=150m/min, Fr=0.1mm/r, ap=0.2mm

Processing method: Dry cutting

Insert grade

Roughness

Tool Life/edge

Halnn BN-K50

≤Ra0.8

450 pcs

Other CBN inserts

Ra1.0

300 pcs


Synchronizer Gear Hub

The material is powder metallurgy. Due to the porous structure, the cutting edge of the cutting tool wears sharply. At this time, Halnn PCBN inserts are recommended. The cutting performance is stable, and the tool life is 45% higher than that other brands CBN tools.


Halnn CBN inserts turning Synchronizer Gear Hub.JPG

Workpiece: Synchronizer Gear Hub(Finishing)

Material: Powder metallurgy

Insert Type: BN-K50 DCGW11T304

Cutting parameters: Vc=500m/min, Fr=0.1mm/r, ap=0.2mm

Processing method: Dry cutting

Insert grade

Tool Life/edge

Efficiency

Halnn BN-K50

145 pcs

Improved 45%

Other CBN inserts

100 pcs

/


Wheel hub

The material is aluminum alloy. Halnn PCD tools are recommended. The cutting performance is more stable, the tool service life is longer, and the efficiency and cost are improved. Halnn can provide non-standard customized services.

Halnn PCD inserts turning Wheel hub.png


Pistons

The material is aluminum alloy. Halnn PCD tools are recommended, which can be processed at high speed, with stable product quality, high precision and long life. And provides non-standard customization services.


Halnn PCD inserts turning Pistons.png

Camshaft

Specification range

Diameter: 320-800mm

Width range: 15-60mm

Customized external milling cutterhead according to customer crankshaft.



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Insert Type


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Applications

The diameter of insert: 320mm              Cutting speed: 120m/min             Cutting depth: 5 mm

Feed rate:0.15mm/min                     Machine: Special machine

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Crankshaft


Non-standard insert


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Product feature

1. The insert adopts high toughness matrix with high quality CVD coating to provide higher processing efficiency and tool life;

2. Grinding precision insert combined with optimized tooth arrangement design, to make workpiece surface achieving the pre-grinding standard;

3. Cutting parts adopt segmented modular installation design, easy to unload and adjust;

4. Excellent cutting performance, to achieve a high chip removal efficiency.


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Process Case

Comparision testCurrent ToolHALNN Tool
                                                Insert

European

134-C03 48 Pieces

122-C03 16 Pieces

H3-03 16 Pieces


680-002X12012060A10  HPA035B

680-002N14009507R34 HPA035B

HolderMSDNN2020K12 D280 Cutterhead
Vc(m/min)140140
N(min-1)159159
f(mm/rev)//
F(mm/min)477477
ap(mm) 3-43-4
ae(mm) //
Type of coolingDry-typeDry-type
Tool wearNormal wear/side milling insert broken edge(Must change insert by processing 300 workpieces)Normal wear (Must change insert by procesing 300 workpieces)
tool life/cutting edge300 psc/cutting edge300 pcs/ cutting edge


Product name: Crankshaft

Processed material: 42CrMo

Material hardness: HB256-295

Machine type: special machine

Industry type: Automobile industry

Customer requirement: improve processing surface quality, reduce tool cost

Comprehensive evaluation: Meet customer roughness requirement. According to the tool wear analysis, The Halnn tool wear is lighter than the current tool, still could continue processing. There is no breakage, just normal wear, solve the anti-breakage property of insert. Improve the stability of cutting tools.


Crankshaft Deep Hole Drilling


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Product advantages:

  • The latest designed four-plane drill tip ensures good chip breaking effect;

  • Special groove and edge treatment, excellent chip holding capacity and smooth chip removal;

  • The use of cross-edge thinning technology greatly reduces axial resistance;

  • Selected heat-resistant and wear-resistant coatings greatly increase tool life;

  • For oil mist cooling, large-hole inlet rods are selected for better lubricity.


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Application range:

    Processing diameter range: 12D-50D

    Effective drilling depth: 400mm

Application cases:

Workpiece: crankshaft                 Workpiece material: 42CrMo

Hardness: HRC28-32                     Drilling depth: 150mm

Machine: vertical machining center

Drilling method: continuous machining

Comparison testOriginal insertsHalnn inserts
Diameter

D8 internal coolant 

deep hole drill

D8 internal coolant 

deep hole drill

Vc(m/min)62.8m/min62.8m/min
F(mm/min)500mm/min500mm/min
n(r/min)2500r/min 2500r/min
Processed Quantity180 pcs220 pcs

Results: Under the same processing parameters, the life of Halnn’s insert increased by 22%.

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WhatsApp:8613271562251

Email:service@halnn-group.com

Address:R & D 5B, National University Science and Technology Park, National University, Changchou Road, Zhengzhou High-tech Zone

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