Project Overview
The workpiece presents several technical hurdles that standard ISO tools often fail to address:
Thin-Walled Construction: The housing is prone to vibration and thermal deformation during high-speed cutting.
Complex Geometry: Multi-angle hole distribution requires tools with exceptional reach and stability.
Space Constraints: Limited clamping space prevents the use of angle heads, necessitating custom-length tooling solutions.
Material Abrasiveness: High-silicon ADC12 causes rapid tool wear, leading to frequent downtime.
| Component Name | Steering Gear Housing |
|---|---|
| Workpiece Material | ADC12 Aluminum Alloy (High Silicon Content) |
| Industry Segment | Automotive Tier 1 – Steering Systems |
| Equipment Type | 5-Axis CNC Machining Center (or 4th Axis setup) |
| Spindle Interface | HSK63 High-Rigidity Interface |
| Core Challenges | Thin-walled structure, clamping deformation, and multi-angle hole distribution. |
Sundi’s Integrated Tooling Solution
We developed a complete suite of customized PCD tools to optimize every stage of the machining process:
Station a: Precision Internal & External Step Boring
This stage focuses on efficient stock removal for internal and external steps within the steering gear housing.
The Challenge & Solution:
Restricted Access: Solves a critical “mounting lug” interference issue where standard tool holders fail due to high collision risks.
Ultra-Thin Profile: Features a customized Ultra-Thin Body designed specifically to clear narrow gaps while maintaining rigidity.
Simultaneous Efficiency: Increases throughput by processing internal and external steps in a single pass using a stable HSK63 interface.
Cutting Parameters:
| Operation (OP) | RPM (rev/min) | Vc (m/min) | fz (mm/Z) | Number of Teeth (Z) |
|---|---|---|---|---|
| Step Boring | 3,700 | 692 | 0.2 | 2 |
Station B: Integrated Drilling & Counterboring (Boss Hole)
Efficiency-driven design that combines two operations into a single high-speed pass.
The Challenge & Solution:
Consolidated Workflow: Traditionally requires two tools (drill + chamfer/counterbore). Our solution integrates drilling and spot facing into one step.
Rigid Construction: Features a Butt-Welded design, combining a tough steel shank with a carbide/PCD head for superior vibration damping and cost-effectiveness.
High-Speed Capability: Engineered for extreme cutting speeds (Vc 1500 m/min) in ADC12 aluminum.
Cutting Parameters:
| RPM (rev/min) | Vc (m/min) | fz (mm/Z) | Z (Teeth) |
|---|---|---|---|
| 8000 | 1500 | 0.09 | 2 |
Station C: Master Cylinder Deep Bore Finishing
High-stability solution designed for small-diameter, deep bore applications.
The Challenge & Solution:
Deep Hole Precision: Machining deep, small-diameter holes often leads to tool deflection and vibration. This tool is engineered specifically to overcome these rigidity challenges.
Integrated Guide Pads: Features a specialized Support design with guide pads that stabilize the tool within the bore, ensuring exceptional straightness and surface finish.
Dual-Function: Efficiently combines precision boring and chamfering operations in a single tool layout.
Cutting Parameters:
| Operation | RPM (rev/min) | Vc (m/min) | fz (mm/Z) | Z (Teeth) |
|---|---|---|---|---|
| Boring | 3000 | 1200 | 0.1 | 4 |
| Chamfering | 3000 | 600 | 0.05 | 4 |
Station D: Deep Reach Helical Milling (Restricted Access)
High-removal solution for deep cavities where angle heads are restricted.
The Challenge & Solution:
Space Constraint: The application requires a deep cut (~110mm) in a confined space where standard angle heads cannot be used due to fixture interference.
High MRR Design: Features a Helical Insert Arrangement (spiral design). This “Corn Cob” style layout allows for aggressive material removal (high MRR) and stabilizes cutting forces over the long overhang.
Heavy Roughing: Specifically engineered for large stock removal in a single efficient pass.
Cutting Parameters:
| RPM (rev/min) | Vc (m/min) | fz (mm/Z) | Z (Teeth) |
|---|---|---|---|
| 6000 | 950 | 0.1 | 3 |
Station E: Precision Multi-Step Fine Boring
Streamlined finishing for complex stepped bores with extreme cutting speeds.
The Challenge & Solution:
Cycle Time Reduction: Engineered with a Multi-Edge Design specifically to minimize machining time per part.
Tool Consolidation: Integrates multiple small steps into a single complex profile. This replaces multiple standard ISO tools, significantly reducing tool change time.
Optimized Geometry: Features varied geometric angles to ensure consistent, high-precision surface finishes across different bore diameters.
Cutting Parameters:
| RPM (rev/min) | Vc (m/min) | fz (mm/Z) | Z (Teeth) |
|---|---|---|---|
| 6000 | 1800 | 0.15 | 2 |
Station F: Modular Multi-Function Compound Tool
Ultimate versatility featuring a detachable milling head and exchangeable cartridge system.
The Challenge & Solution:
Complex Geometry: The part requires boring, bottom facing, and large-diameter face milling. Doing this with separate tools would drastically increase cycle time.
Cost-Effective Maintenance: Features a Modular Design where the milling head is separate from the shank. Crucially, it uses Exchangeable Cartridges for the milling inserts. If a crash occurs or seats wear out, you replace only the cartridge, not the expensive tool body.
High-Density Cutting: The multi-edge design allows for higher feed rates and reduced cycle times across all three operations.
Cutting Parameters:
| Operation | RPM (rev/min) | Vc (m/min) | fz (mm/Z) | Z (Teeth) |
|---|---|---|---|---|
| Boring | 5500 | 1500 | 0.07 | 4 |
| Bottom Face | 5500 | 1500 | 0.01 | 4 |
| Face Milling | 6500 | 5500* | 0.2 | 4 |
Station G: High-Speed Lightweight Trepanning Compound Tool
Advanced lightweight design utilizing 3D printing technology for extreme cutting speeds.
The Challenge & Solution:
Advanced Manufacturing: To solve the rigidity issues inherent in thin-walled tools, we utilized 3D Printing and Laser Cutting technologies. This allowed us to create a complex, lightweight geometry that is impossible to manufacture with traditional methods.
Structural Optimization: The optimized design features a specialized Rib/Web Structure . This reinforcement drastically increases rigidity and dampens vibration, even with the tool’s thin walls.
Cost-Smart Design: Adopts a Split Modular Design where the cutting head is separate from the body, reducing long-term consumable costs.
Cutting Parameters:
| Operation | RPM (rev/min) | Vc (m/min) | fz (mm/Z) | Z (Teeth) |
|---|---|---|---|---|
| Trepanning | 9500 | 3500 | 0.18 | 2 |
| Drilling | 9500 | 2350 | 0.12 | 2 |
Station H: Integrated Drill-Mill-Bore Compound Solution
A 4-in-1 powerhouse capable of drilling from solid and finishing in a single pass.
The Challenge & Solution:
Drilling from Solid: Unlike standard reamers that require a pre-hole, this tool is designed for Solid Machining . It features an exchangeable drill insert tip to handle the heavy removal work cost-effectively.
4-in-1 Process Integration: Drastically reduces cycle time by combining four distinct operations: Drilling + Rough Boring + Fine Reaming + Back Chamfering.
Hybrid Technology: Smartly combines two technologies:
Indexable Inserts for the drill tip (lowering consumable costs).
Brazed PCD Body with a multi-edge design (Z=4 for Reaming) to ensure high-precision surface quality and extended tool life.
Tool Capabilities & Specs:
| Operation Zone | Function | Effective Teeth (Z) | Feature |
|---|---|---|---|
| Tip | Drilling | 2 (Insert) | Replaceable Tip for Cost Saving |
| Body | Rough & Fine Bore | 4 (PCD) | High Stability Reaming |
| Shank/Neck | Back Milling | 2 (PCD) | Back-Chamfering Capability |
Proven Results & Efficiency
Cycle Time Reduction
Decreased from 200 seconds to 140 seconds per part.
Enhanced Stability
Eliminated vibration-related scrap on thin-walled sections.
Tool Life Extension
Multi-blade PCD designs tripled the interval between tool changes compared to previous solutions.
Cost Efficiency
Replaceable-tip designs and composite tools significantly lowered the cost-per-part.
Cost per Part (CPP) Analysis
Lower percentage indicates higher cost-efficiency per part.
Sundi's custom PCD solutions solved our complex interference issues and boosted our production efficiency by 15%.