Automotive turbochargers need to work under high temperature, thermal shock load conditions. At the same time, the complex shape of the turbine shell, high dimensional accuracy and surface quality requirements make it a high-cost part in the automotive processing industry. For the flange surface, outer end face and inner hole of the turbine shell, Gesac has a variety of mature models. The product is adapted to the turning, milling and drilling tool that meets the customer’s working conditions for processing, as shown in Figure 1 and Figure 2.
This processing case is the processing of the large end ring groove and the outer circular end of the turbine casing. The processing position is shown in the red area of Figure 3. The processing position accuracy needs to be within ±0.1mm, the surface roughness value is required to be Ra=3.2μm, and the workpiece material is resistant to Hot alloy, the processing process is forming, the cutting force is large, the tool is easy to wear, and it is easy to vibrate.
The slot insert and shank customized from the TGND project are used for processing. The processing method is to perform continuous super-finishing on the machined surface such as the groove top arc and the groove bottom contour. The tool is shown in Figure 4.
The processing information is as follows:
Processing part: big end ring groove and outer circle end of turbine shell
Part material: heat-resistant alloy, hardness HB165-175
Machine tool: vertical lathe
Cooling method: water-based emulsion/external cooling
Machining type: External groove machining
Tool: TGNDP4M333LG101-GP4225
Cutting parameters: N=380r/min, V=117m/min, F=27mm/min, ap=0.5mm
Processing effect: high processing efficiency, no burrs on the edge, and long chips. After the trial cutting, the customer’s size is fully checked and the blade life meets the customer’s requirements. The machining effect is shown in Figure 5, and the tool wear is shown in Figure 6.
