Tooling solutions for machining of cylinder block in ISO K and ISO N materials
| Aluminium block | Cast iron block |
The cylinder block is the component that serves as the main structure of the engine and it is the housing of several different moving parts that together generate the power to move the vehicle.
For many years, the engine block has been manufactured using cast iron alloys due to its strength, low cost and wear resistance. But as engines become more complicated, new materials have been taken in use to reduce its weight as well as to increase strength and wear resistance. Today´s most common materials for passenger car engines are aluminium alloys, because of their reduced weight and excellent casting properties. Commercial vehicles will continue to use cast iron, but in more high-strength alloys.
The manufacturing process of cylinder blocks involves the largest number of machines in automotive component production. There are also several complex processes and tight tolerances involved. The high demands in quality for cylinder blocks is crucial for the performance of the vehicle. Cost-efficient manufacturing is of great importance for these types of components.
Besides our extensive offer, Sandvik Coromant also have dedicated products and engineered solutions that fully support overtaking the challenges manufacturing these components presents.
Tooling solutions that support the manufacturing of cylinder blocks:
ISO K solutions
CoroMill® 745 – multi-edge face milling cutter for best production economy
The patented insert positioning system provides the same light cutting action and performance as a positive single-sided milling cutter, but with a total of 14 cutting edges.
CoroMill® 425 – finishing concept for cast iron face milling
Specifically designed for the automotive business. The accurate and reliable adjustment system makes CoroMill 425 the easiest to use system on the market.
CoroMill® 331 – multi-purpose side and face milling cutter
CoroMill 331 is a multi-purpose side and face milling cutter with high-precision capability for numerous operations. The cutter is the most productive of its kind for producing grooves and for parting off.
CoroMill® MS40 – the ultimate tangential milling solution
CoroMill® MS40 is a true 90-degree cutter designed for accurate and reliable side milling and repeated passes. The outcome is flawless walls with precise dimensions, minimal roughness and perfect perpendicularity.
CoroDrill® 460 – multi application drill
CoroDrill 460 is a multi-application, high performance drill that can be used across a wide range of materials. This drill provides high capacity utilization, flexibility and versatility.
CoroDrill® 860 – optimized multi-material drilling solution
CoroDrill® 860 with -GM geometry is a high-performance drilling solution for short holes primarily in ISO P, M, K and H materials. It performs competitively in ISO N and ISO S materials as well. The drill offers robust process security, high hole integrity and excellent tool life
CoroDrill® 880 indexable drilll
CoroDrill 880 with its unique insert geometries and configuration creates a balanced, step-by-step entrance into the workpiece. This reduces cutting forces to less than half of typical insert drills, and virtually eliminates deflection on entry.
CoroDrill® 400 and 430 – flexible and precise drilling solutions
Customized tooling for the automotive industry. The straight flute CoroDrill 400 and 3 flute CoroDrill 430 provide highly productive hole-making in GCI, CGI and nodular cast iron, resulting in low cost per hole.
CoroTap® 100 KM – straight flute tap
Superior tool life and high productivity are just some of the benefits offered by this exceptional tool. Suitable for both through and blind holes.
CoroTap® 200
CoroTap 200 feature spiral point taps for through holes designed to push the chips forward. The range includes versatile taps for various materials and optimized taps for specific materials and applications. Tailor Made and Advanced Engineered tools are available within the Customized solutions range.
CoroTap® 300
CoroTap 300 is a range of spiral flute taps suitable for tapping in blind holes up to 3 × D. There are different helix angles suitable for different applications. The range features versatile taps for various materials and optimized taps for specific materials and applications. Tailor Made and Advanced Engineered tools are available within the Customized solutions range.
CoroTap® 400
CoroTap 400 is a high-speed, chip-free forming tap suitable for both through- and blind-holes in steel, stainless steel, aluminium and HRSAs. Versatile and optimized forming taps are available, with and without oil grooves, in an assortment of diameters, grades, coatings and thread forms to suit a range of applications.
B685 – stable and productive cylinder boring, from roughing to semi-finishing
Cylinder boring is a key operation in the automotive industry; a high-speed operation with high requirements on tight tolerances. Until now, the operator has adjusted the insert position manually, which is a time-consuming procedure and often requires special devices.
B687 – stable and productive finishing cylinder boring
The B687 cylinder boring bar is designed for productive and stable finishing. The cutter is available in different designs depending on operation. Use the three-cartridge design for reliable performance in under-coolant applications.
B681 – stable and productive roughing cylinder boring
B681 is designed and developed for roughing in cylinder boring operations. The solution produces excellent roundness and cylindricity, allowing for a smooth semi finishing operation due to the integrated Silent Tools™ damped adaptors.
More about the B681 roughing cylinder boring
B683 - stable and productive semi finishing cylinder boring
B683 is designed and developed for semi finishing in cylinder boring operations. The solution produces excellent roundness and cylindricity, allowing for a smooth finishing operation due to the integrated Silent Tools™ damped adaptors.
More about the B683 semi finishing cylinder boring
ISO N solutions
CoroDrill® 400 and 430 – flexible and precise drilling solutions
Customized tooling for the automotive industry. The straight flute CoroDrill 400 and 3 flute CoroDrill 430 provide highly productive hole-making in aluminium, resulting in low cost per hole.
CoroDrill® 880 indexable drill
CoroDrill 880 with its unique insert geometries and configuration creates a balanced, step-by-step entrance into the workpiece. This reduces cutting forces to less than half of typical insert drills, and virtually eliminates deflection on entry.
CoroMill® Century – light cutting face mill for high speed finishing
CoroMill Century is a face mill tool system with aluminium or steel body for high speed machining. The tool is designed with serrated insert interface for safe performance and reduced run-out.
CoroMill® Century – bi-metal machining process without burring, chipping or scratching
Many modern engines use cylinder blocks that consist of grey cast iron liners casted together with aluminium. This makes machining engine block deck faces a considerable challenge.
Read more about Bi-metal machining process
M5B90 – super finishing face milling cutter for aluminium
Finishing face milling concept developed for automotive aluminium components such as cylinder heads, blocks, housings, covers and all components with a wide material engagement.
Learn more about M5B90 milling cutter
M5C90 – one shot face milling cutter for aluminium
M5C90 is a concept face milling tool for high speed direct finishing of aluminium automotive parts such as cylinder heads, cylinder blocks, and all aluminium parts within wide cutter engagement.
More about M5C90 milling cutter
M5F90 – one shot roughing and finishing of thin wall aluminium parts
M5F90 is a concept face-milling cutter that enables roughing and finishing of thin wall automotive aluminium components in a single operation.
More about the M5F90 milling cutter
M5Q90 – for first stage roughing operations
M5Q90 cleans the surfaces of newly casted aluminium cylinder heads and engine blocks in one smooth operation, without burring.
More about the M5Q90 milling cutter
M5R90 – a new solution for roughing and semi-finishing of aluminium automotive parts
M5R90 is the first choice for roughing to semi-finishing in shoulder milling operations of automotive aluminium components such as cylinder blocks, cylinder heads, transmission housings.
Read more about M5R90 milling cutter
M610 – new milling cutter for finishing bi-metal materials (Al and GCI)
M610 is a stand alone product for finishing milling of bi-metal engine deck face in engine blocks with GCI liners, bed plates (inserts in GCI) and all other automotive bi-metal parts with inserts in GCI, without chipping, burring or scratching.
More about the M610 milling cutter
B685 – stable and productive cylinder boring, from roughing to semi-finishing
Cylinder boring is a key operation in the automotive industry; a high-speed operation with high requirements on tight tolerances. Until now, the operator has adjusted the insert position manually, which is a time-consuming procedure and often requires special devices.
B687 – stable and productive finishing cylinder boring
The B687 cylinder boring bar is designed for productive and stable finishing. The cutter is available in different designs depending on operation. Use the three-cartridge design for reliable performance in under-coolant applications.
B681 – stable and productive roughing cylinder boring
B681 is designed and developed for roughing in cylinder boring operations. The solution produces excellent roundness and cylindricity, allowing for a smooth semi finishing operation due to the integrated Silent Tools™ damped adaptors.
More about the B681 roughing cylinder boring
B683 – stable and productive semi finishing cylinder boring
B683 is designed and developed for semi finishing in cylinder boring operations. The solution produces excellent roundness and cylindricity, allowing for a smooth finishing operation due to the integrated Silent Tools™ damped adaptors.
More about the B683 semi finishing cylinder boring
CoroTap® 100 KM – straight flute tap
Superior tool life and high productivity are just some of the benefits offered by this exceptional tool. Suitable for both through and blind holes.
CoroTap® 200
CoroTap 200 feature spiral point taps for through holes designed to push the chips forward. The range includes versatile taps for various materials and optimized taps for specific materials and applications. Tailor Made and Advanced Engineered tools are available within the Customized solutions range.
CoroTap® 300
CoroTap 300 is a range of spiral flute taps suitable for tapping in blind holes up to 3 × D. There are different helix angles suitable for different applications. The range features versatile taps for various materials and optimized taps for specific materials and applications. Tailor Made and Advanced Engineered tools are available within the Customized solutions range.
CoroTap® 400
CoroTap 400 is a high-speed, chip-free forming tap suitable for both through- and blind-holes in steel, stainless steel, aluminium and HRSAs. Versatile and optimized forming taps are available, with and without oil grooves, in an assortment of diameters, grades, coatings and thread forms to suit a range of applications.
* For engineered tooling solutions, please contact your local Sandvik Coromant sales representative.
