The efficient partner South Korea Hyundai Motor Company established the company’s largest overseas manufacturing plant in Chennai in India. The plant began production in the spring of 1998 and is now the second largest and fastest growing automobile manufacturer in India and becomes Domestic industry technical standards setters. The models manufactured include Santro, Accent and Sonata, covering the entire range from sedan to luxury sedan, with an engine capacity of 100~2000cc. Chennai is a full-scale manufacturing company with production lines, aluminum foundry, paint shop, pressure lines, plastic parts manufacturing plants, assembly facilities, etc. Among them, the flexible production line can process multiple models with a processing capacity of 120,000 cars per year for quality inspection. It also has highly automated facilities.
Sandvik Coromant is part of the Sandvik Group and is one of the world's largest metal cutting tool companies. Hyundai Motor (India) Co. and Sandvik Coromant have been cooperating since the commissioning of the Chennai plant and have now formed an efficient partnership. The continuous improvement of production efficiency, the improvement of quality consistency and the reduction of processing costs are all related to the high quality tools and correct tool solutions offered by Sandvik Coromant.
One example of a significant improvement in the production of faultless linkages is the production of engine linkages for the Santro and Accent models. The connecting rod production line is always under pressure—to ensure optimal efficiency, the expected production volume is completed on time, so that the number of parts required for engine assembly can be supplied in a timely manner. To this end, engineers have set a higher goal, namely to achieve trouble-free production of connecting rods, which is the key to uninterrupted production. In the past, there were chip control problems such as chip jamming cutters and other interference phenomena. For this reason, the operator must always remove the jammed chips from the tool and the conveyor belt, and even lead to long downtime and affect the increase in output.
Hyundai Motor (India) and Sandvik Coromant engineers discussed how to improve the control of chip and safety issues and improved the drilling performance of steel connecting rods (materials CMC02.2, 245-300HB). Coromant Delta drills, with a 16.01mm diameter cutter for the Santro model, and a 17mm diameter cutter for the Accent model. The 411.5-type drill is a welded carbide drill with a unique top groove shape with internal cooling fluid that allows for efficient drilling of small tolerance holes in the 9.5 to 30.4mm diameter range. The standard drilling depth is 3.5~ of the drill diameter. 5 times while optimizing different processes with custom tools. For coated holes with higher surface finish requirements, this coated drill is ideal. The drill has a special cemented carbide grade suitable for machining steel, cast iron, stainless steel, nonferrous metals and hardened parts.
For the Coromant Delta drills, the cutting speed is 100 m/min, the feed rate is 300 mm/min, the feed per revolution is 0.15 mm, and 1,250 holes are drilled, which is a predetermined tool life for the produced drill bit. After applying this tool to the connecting rod machining process, the chip breaking performance was greatly improved and the tool life was increased by 166% — from the original 11 meters to 30.4 meters. After initial trial link drilling, it was found that machining a 19mm deep hole can achieve better performance. After remanufacturing this Coromant Delta drill, even a longer, predictable 32.3 meter tool life can be achieved. In addition, a consistent quality of processing was obtained after regrind. The processing cost of each part has also dropped from the original 5.26 to 2.44. If processing 120,000 connecting rods, the total annual cost savings is about 230,000 yuan, and there is no longer any problem of chip interference during processing.
Consistency in cylinder bore size Another greatly improved application is the boring of holes in the engine block of the Santro model. In the previous production and processing, the holes of the cylinder block (material made of gray cast iron, CMC08.1, 220HB) had serious inconsistency in size, uneven cutting force, and high noise level. Later, Sandvik Coromant cylinder boring tools with a diameter of 65.80mm were used to machine the workpiece. This custom tool concept provides the correct cutting method for the machining of cylinder bores.
Using TM260.20 type tool to machine 100mm deep hole, cutting speed is 67m/min, feed rate is 225mm/min, feed per revolution is 0.72mm, used blade SDMX 1506ZN, brand name is H13A, hole machined between inserts The number is 400 - the condition is to guarantee predictable 40m tool life and consistent machining accuracy. This custom concept uses lower cutting forces for cutting, greatly improving hole size consistency. The dimensional tolerance of the hole is only +30 microns, which ensures the consistency of the size of the holes and ensures a smooth and even cutting action for high-safety machining.
Corocut being processed
High Speed Manufacturing Support Shanghai Automobile Gearbox Factory IV will mass produce more than 50 different shafts and gears, and will ship more than 150,000 finished products each year to Shanghai Volkswagen's warehouses. Here, turning, cutting and grooving of steel are an important part of the metal cutting process. In order to maintain high-speed, multi-variety production capacity, about 70% of the cutting in the fourth workshop comes from Sandvik. P-Lline inserts, Corocut and Q-Cut knives are used in large quantities, most of which are made in accordance with company-specific requirements. . T-Max P inserts are used in the cutting process of many standard steels, which is the central process of Shanghai Gearbox. When machining small-size shaft parts, the previous tool could only produce 75 parts before the tool needed to be replaced. After installing the GC4125 grade Corocut groove insert and adopting the cutting parameters recommended by the supplier, the tool life was doubled. The tool can continuously produce 160 workpieces without any loss of production quality.
Mass production of high-precision China's Ningbo Yuejin Automobile Front Car Co., Ltd. produces about 60,000 steering knuckles manufactured by Toyota each year, which occupies the workload of five processing centers in the factory. The design of the knuckle requires a series of drills through the steel blanks. For the holes, these holes must have the highest accuracy. The use of Coromant Delta drill bits and the use of cutting parameters recommended by Coromant sales engineers have achieved a level of precision that can only be achieved with multiple processes before drilling with only one drill, which effectively solves the accuracy requirements in mass production and improves Quality and production efficiency.
At present, Ningbo Yuejin Automobile Front Bridge Co., Ltd. is creating a computer-controlled manufacturing facility that combines advanced CAM functions with the existing Unigraphic CAD system, and makes full use of industrial research bases from processing centers in the United States, Germany, Italy, and Japan to develop novelties. And advanced manufacturing technology and production methods. The company’s plan is to once again build Coromant products into the system and make Sandvik tools an integral part of its next expansion.
Shenyang Zhongda Huanxin Refrigeration Technology Co., Ltd.
