Tiger Blade (Tiger·tec) is a new type of hard alloy coated blade for machining cast iron specially developed by Walter Co., Ltd. It is well known that most of the engine's cylinders are made of grey cast iron. Before the advent of the tiger blade, in order to ensure the stability of processing and processing efficiency, many engine manufacturers use ceramic blades for the processing of the cylinder. MAHLE is a manufacturer specializing in motorcycle engines. They also believe that carbide tools are difficult to meet their processing needs. Their cylinder bores are made of grey cast iron like the HT250 (internal grade Niresist) with a bore diameter of 80 mm and a hole length of 150 mm. In the rough machining with a single-sided allowance of 2mm, a dedicated double-edged boring tool and a company's ceramic blade SNGN120712SL500 (they sometimes use the SNGN120716 blade for controlling the cutting force), the tool life is 70. Workpieces. The company that supplies their ceramic blades is the leader in European ceramic blade technology and has considerable competitiveness in ceramic tools.
Beginning in 2000, local Walter engineers recommended the tiger blade SNMA120416WAK10 to them, and they were surprised. Although the cutting speed of 375m per minute of the tiger blade is slightly lower than the cutting speed of 500m per minute of the ceramic blade, since the feed rate is increased from 0.2mm per tooth of the original ceramic blade to 0.27mm per tooth, the processing efficiency is higher than that of the ceramic blade. Slightly higher (1.25%). Under such conditions, the life of the Walter Tiger Blade can also reach 70 pieces steadily, sometimes even 80 pieces. It can be said that it is not inferior in terms of life compared with ceramic blades. At the same time, because the toughness of cemented carbide inserts is higher than that of nitride ceramics, the blade of the tiger has not suffered from the frequent occurrence of edge cracking. MAHLE processors no longer need to carry out frequent and strict monitoring. Since the price of tiger blades is much lower than that of ceramic blades, MAHLE's economic benefits after using tiger blades are very obvious. Before adopting Walter's tiger blades, the annual cost of the blades they used to purchase the process was about 51,000 euros. When the tiger blades were used, the cost of processing the blades for the process had been reduced to 40,700 euros, a drop of more than 20%. . Through this technological revolution, MAHLE not only directly reduced the cost of tool procurement, but also reduced the risk of chipping in the machining process, and reduced the variety of tools (no need for two different tool nose arc radii), The large tool nose arc radius increases the level of surface roughness and reduces the grinding time of the subsequent process.
Tiger blades generally improve engine manufacturer productivity by using carbide inserts to machine engine cast iron.
GKN is one of the world's leading auto parts manufacturers, and they have an engine block production line in their UK plants. The GKN UK plant has long used the SNMA150616-KRGC3015 blade of a well-known tool company for roughing the cylinder, which consumes about 5,000 pieces per year. The production of GC3015 is the world leader in the cutting tool industry, and the great achievements in the cutting industry are obvious to all. Before the trial of the Walter Tiger Blade, many tool suppliers tried to replace the GC3015 blade there, and these attempts ended in failure. This situation led to the conclusion that the metal cutting experts at GKN's UK factory even came to the conclusion that the GC3015 blades they used were irreplaceable, and that when Walter experts recommended the tiger blades to them, they did not want to believe in the power of the tiger blades. However, Walter experts fully introduced the successful experience of the Tiger Blade and agreed to follow the cutting test under the conditions of GKN (these conditions are considered to be almost harsh and unimaginable). GKN British experts finally agreed to carry out the cutting test. . The trial was a complete success. When GKN UK used the GC3015 insert, it used a cutting speed of 170m/min and a feed rate of 0.6mm/r. The cutting speed was increased to 285m/min when the Walter Tiger blade was used, and the feed rate was also increased to 0.8. Mm/r, while the depth of cut is still maintained at a level of 5 mm. We know that the usual increase in cutting speed will mean a sharp drop in tool life, such as a 25% increase in cutting speed and a reduction in tool life of about 40% in machined workpieces. Walter's tiger blades, after increasing the cutting parameters in this way, have the same tool life as the GC3015. Although the price of the tiger blade is much more expensive than the GC3015, the GKN UK factory still decided to replace the GC3015 blade with the Walter Tiger Blade due to the increased processing efficiency. Because the processing efficiency of the Walter Tiger Blade has increased to about 224% of the original GC3015, thereby greatly saving processing costs. With the added cost of buying tools, GKN UK will reduce manufacturing costs by £387,300 per year.
John Deere is a US company that manufactures agricultural vehicles, construction vehicles, and engines and their components. Some of their engine cylinder heads are made of cast iron. They originally used a well-known 6K5A06R01 milling cutter known as the milling tool for finishing. The cutter with a diameter of about 152mm uses 10 general blades (LPE324-03) and 2 polishing blades (LPE324-0wipers). Is 722. When the cutter was used, they were processed at a cutting speed of about 274 m/min and a feed rate of 0.13 mm/Z at a feed rate of 873 mm/min. With Walter's tiger blade, the cutting speed is increased to 305 m/min, the feed rate is maintained at 0.127 mm/Z, the feed rate is increased to 965 mm/min, and the wiper blade is not required for machining with Walter tools. John Deere's metalworking experts were very pleased that the Tiger Blades became their only logical choice in the project, for which they purchased seven Walter milling cutters. Because of the use of tiger blades, their tooling costs were reduced by 55%, and the overall processing cost was reduced by approximately 6.5% due to reduced tooling costs and increased processing efficiency. The use of tiger blades reduces their processing costs, reduces tooling costs, improves machining quality and simplifies tool management.
What makes the tiger blade provide higher cutting speeds than rough in the case of roughing cast iron? Walter's technical department made its own explanation. They said that first of all, plating technology played a major role. Practice has shown that black alumina coating is the best choice for processing cast iron, especially for rough cast iron. Moreover, we can see from Figure 4 that the thickness of the alumina coating is inversely proportional to the occurrence of comb cracks. However, since the thick plating layer will damage the bonding force of the plating layer, the conventional plating of the tool is generally thin. The researchers of Walter Tiger Blades have developed a special intermediate layer through a large number of research experiments, which improves the bonding strength of the coating and allows the thickness of the coating to be increased, so that the more durable alumina coating is fully utilized. At the same time, the cemented carbide substrate has been further improved to make it more wear resistant. The high cutting speed and process reliability of the tiger blade is largely due to the combination of the alumina coating with a modified tungsten carbide matrix through a special intermediate layer. It is worth noting that the results of the test at Tuebingen, where the Walter Group headquarters is located, show that the improvement of the wear resistance and the mitigation of the comb-like cracks have greatly improved the cutting performance of the tiger blade. This is why tiger blades have superior wear resistance when machining cast iron.
Black and gold color combinations are also highly practical, says Walter's Joerg Drobniewski, who is involved in the development of tiger blades. "There is no doubt that when roughing cast iron, carbide inserts with alumina coating should be the first choice. The downside is that the black coating makes the traces of wear illegible." According to JoergDrobniewski, this is the magic weapon for the tiger blade: "With the black rake face and the golden flank, we can effectively identify the wear of the tool" .
With a tiger blade for roughing cast iron, Walter has made a huge revolution. Usually the famous international tool companies have certain competitive advantages. Our case comparison shows that in these occasions, our specific products are more suitable than the competitors that the customers originally used. At least in practical applications, the Tiger Blade has achieved a dramatic development in the processing of cast iron carbide inserts, achieving the cutting efficiency and service life previously only possible with ceramic inserts, with significant competition in terms of economics. Advantage.
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