The Milling Mechanism And Application Research On CGI

The HX type cylinder head is a key part of the diesel engine used in HX type high power diesel locomotive, which is a typical box structure with multiple faces and holes. Its structure is complex and accuracy requirement is high. In order to adapt to the high performance required by the diesel engine, HX type cylinder head chooses Compacted graphite iron is chosen as the HX type cylinder head material which is difficult to machine. Among all the machining processes, the milling operation is a critical and influences the machining efficiency significantly.This research is based on the current production demand, aiming at promoting the milling efficiency. In the milling test H13A uncoated insert and GC 1020 coated insert from Sandvik was used, and the milling mechanism on the Compacted graphite iron was analysed in terms of chips form, cutting force, tool wear and the finished surface quality. After choosing reasonable inserts and obtaining optimized parameters with the consideration of real production, we can get reasonable and optimized process parameters for HX type cylinder head. Meanwhile, this research carries out the finite element simulation analysis on the Compacted graphite iron milling mechanism to guide the practical application. 1.According to the characteristic of Compacted graphite iron, H13A uncoated insert and GC1020 insert was chosen it this research. Orthogonal experimental design method was applied with three factors—cutting speed, feed rate and cutting depth which all are divided into 4 different levels.2.The cutting chip form, cutting force, tool wear and surface machining condition were evaluated and analysisd and a multiple-factors interactive and regressive model was built where cutting force and surface roughness(Ra) is a function of cutting parameters to deeply understand the milling mechanism of Compacted graphite iron.3.According to test data, the cutting parameters was optimized through optimizing multiple targets then the parameters was applied in the cylinder head machining. the application result was evaluated and the parameters was popularized.4.Modeling simulation research was carried out based on the test data to verify the reliability of the test conclusion on the Compacted graphite iron in theory.