In the body of a car, most aluminum parts are concentrated in the air conditioning system, engine hood, shock absorber parts, and steering column. In the chassis and suspension assembly, aluminum parts are mainly concentrated in the wheels, suspension brackets, and steering system components. In the power transmission system, most aluminum parts are located on the cylinder head, cylinder block, engine cover, pump, and cooling system. In addition, the application of aluminum alloy in seals, body shells, and chassis is also increasing.
Replacing steel with materials of lower density as conventional structural materials is also important in other industries, such as general machinery manufacturing and aerospace industry. However, due to the low hardness of aluminum alloy and its high toughness, its cutting processing is rather difficult. During processing, aluminum alloy is easy to adhere to the tool material and cold work hardening phenomenon may occur. Therefore, chips are easily produced on the front face of the PCD cutter during low-speed cutting.
Due to sensitivity to environmental impact, more and more automotive parts are using dry cutting or minimal cooling fluid during processing. The drive to save cooling costs (including related waste liquid recovery treatment costs) is also promoting a significant increase in the cutting speed, which cannot be achieved with conventional hard alloy cutting tools.
With conventional tools or tool materials for dry cutting, due to the change of the cutting edge geometry of the PCD cutter and the increase in heat caused by friction in the cutting area, the surface smoothness of the workpiece being processed is poor.
The development of machine tool technology has continuously increased the spindle speed and feed rate, thereby achieving faster cutting processing. Just a few years ago, the spindle speed of machine tools was only 6000 r / min, but now it has reached 30000M-40000r / min, and the axis movement acceleration can reach 2G.
With the support of powerful computer capabilities, such machinery can achieve the required motion functions for processing (such as helical interpolation motion in thread milling).
To convert this speed advantage into processing advantages at the point of operation, corresponding tool materials need to be used. However, if hard alloy cutting tools are used, the cutting speed can only reach 400m / min. Tools with polycrystalline diamond (PCD) cutting edges can achieve cutting speeds of up to 3000m / min (depending on the cutting process).
In addition to higher processing speeds, the main advantages of PCD cutting tools include longer tool life and (in many cases) better surface processing quality.
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