Dry machining of cast aluminium automotive wheels - innovative cutting tool design for improved machining performance and environmentally conscious manufacturing

摘要

Environmentally conscious, coolant-free dry machining technologies have emerged in recent years as viable alternatives to the traditionally known machining processes involving flood-cooling methods. Contour turning of cast aluminum wheels in the automotive industry poses significant challenges in process and product innovation for improved machining performance, particularly with the pressing need for chip control for defect-free cast aluminum products. Thus a further study is required regarding the design and development of an innovative cutting tool, which is essential for facilitating the favorable chip flow leading to improved chip control. The anticipated broader functionality of the new tool design is also to facilitate a coolant-free dry machining process. This paper will present the results of a recent analytical and experimental study involving the use of an analytical model for predicting the chip flow direction and comparison of predictions with experimentally observed chip flow using high speed filming techniques. The identification of "problem areas" during the contour turning of the wheel profile led to process innovations in machining and a new product development, with great economic impact and also promotes a change toward environmentally conscious machining. This paper presents the details of this process improvement and the development of a new, innovative cutting tool design to provide coolant-free dry machining with improved chip control in contour turning of cast aluminum wheels used in the automotive industry. Shop floor tests using the new cutting tool show significant improvements in chip flow and machining performance.