Exhaust manifolds is the part of an engine that supplies the air to the cylinders. The function is to collect engine exhaust from multiple cylinders and deliver it to a treatment system so as to avoid environmental detriment. Exhaust manifolds are generally made from cast iron or nodular cast iron materials. In recent years, due to light weight, durability and smooth inner wall and low exhaust resistance, it have been applied in automotive industry more and more massively.
Here is the solution for exhaust manifolds machining
Workpiece Material: Nodular Cast Iron HB200
Technical Process
■Milling face of large flange
■Hole making for large flange
■Milling and hole-making for flange face of supercharger
■Pipe orifice machining
1、Milling face of large flange
Cutter body：FME03-125-B40-SP12-08
Rough milling
insert：YD201/SPKN1203EDTKN
cutting data： V=100m/min , fz=0.15~0.24mm/z ，ap=3~4mm；
Finish milling
Insert：YD201/SPKN1203EDFR，
YD201/SPEX1203EDR-1(with wiper)。
Cutting data：V=100m/min , fz=0.1mm/z，ap=0.5mm。
2、Hole making for large flange
There are three main dimension, they areΦ13.1X6 (hole number), Φ11X1 (it is a elliptical hole and drilling first then milling)
Drilling:
Tool：1105SC03-1310,1105SC03-1100
Cutting data：n=1400~1600r/min , fr=0.2~0.3mm/r；
Elliptical hole Milling
Tool：PM-2E-D6.0
Cutting data：n=7000r/min , fz=0.04mm/z；
3、Milling and hole-making for flange face of supercharger
Flange face: Requiring sharp cutting edge and low cutting force
Tool：FMA04-125-B40-OF05-08
insert：OFKT05T3-DF/YBG102
Cutting dataCutting data：V=210m/min，fz=0.2mm/z
Drilling on small flange:
Tool 1105SC03-1050
Cutting data：n=1400~1600r/min , fr=0.2~0.3mm/r；
4、Pipe orifice machining
Face Milling
Tool：FMD02-080-B32-PN11-10
Insert：YBD152/PNEG110512R-CM
Cutting data：V=100m/min , fz=0.15mm/z ，ap=2mm；
Rough Boring
Tool： Rough boring tool with two
doublecutting edges
Insert：YBD151/CCMT09T304-HM
Cutting data：V=150m/min，fz=0.2mm/z
Finish Boring:
Tool： Innovative precision boring tool
Insert：YNG151/TBGH060102L
Cutting data：V=180m/min，fz=0.1mm/z
