Development And Production Application Of PCD Thread Mill Cutter

This thesis originated from L850 cylinder head line Continuous Improvement Project of Shanghai General Motors Co., Ltd. The cylinder head line was used traditional hard metal thread mill cutter to process the screw thread of the tensioner mounting hole on the front side of cylinder head which is on all aluminum L850 engine. Because PCD compact have the same superiority like diamond, such as high hardness, high-heat conductivity, low friction coefficient, low thermal expansion coefficient, and more over PCD compact also have the better strength and ductility as hard metal. When cutting aluminum alloy material, hard metal cutters' wear life is about only 5% of PCD cutters', and cutting speed of PCD cutters is about three times as that of hard metal cutters. Because of so many advantages of PCD cutters, so we choose PCD as the material of cutter head. In order to achieve the targets, which are productive efficiency dynamic improvement and cutting cost down, PCD thread mill cutter was developed.The PCD thread mill cutter is designed under the guidance of the cutter finite element simulation software AdvantEdge. Considering about the structural design, blade design, tool material selection, welding and process after welding and other considerations, referencing to the geometric shape of L850 thread milling cutter, we choose a two PCD blade weld thread mill cutter as our final design. PCD thread mill cutter has been made based on the previous research work.Assessed by cutting experiment, the optimized strategy for cutting parameters, which provides a good basis for high efficiency and accuracy of thread milling, is put forward by analyzing the cutting force in four process parameters. Assessed by production application experiment, the wear of PCD thread mill cutter is analyzed. Based on wear mechanism, the wear root cause of PCD thread mill cutter is found. Single piece processing cost is determined.