In 2012, the evolution of engine materials brought about significant changes in the industry. Lighter, stronger, and more durable materials became increasingly common, which placed higher demands on cutting tools. The challenge was to produce high-quality engines while maintaining cost-effectiveness. To meet these challenges, Seco has developed a range of efficient, economical, and reliable machining solutions that cover the entire production process.
As consumer demand in the automotive sector continues to rise, manufacturers are under greater pressure to ensure quality while reducing costs. The competition is fierce, and improving processing efficiency and lowering per-unit production costs have become key priorities. Among all components, engine manufacturing—often referred to as the "heart" of the car—remains the most technically complex and critical. With new materials being introduced, cutting tools must now handle even stricter requirements for precision and performance.
For example, the machining of engine cylinder bores requires extremely high accuracy, often reaching H7 or higher. The number of cylinder bores is large, and the process typically involves three stages: rough, semi-finish, and finish boring. To save time, Seco designed a composite tool that combines semi-finish and finish boring into one operation (see Figure 1). This tool uses two small holders for semi-finishing and includes a fine adjustment feature. The final stage uses PCBN inserts, allowing for high-speed cutting. Seco’s patented spiral wiper technology not only enhances tool life but also minimizes vibration, ensuring excellent surface finish. With cutting parameters of Vc=800m/min and Fn=0.3mm/rev, the tool delivers outstanding performance suitable for mass production.
The cylinder head is another critical component affecting engine performance. Its precision directly impacts overall engine efficiency. Maintaining coaxiality between valve seats and bore holes is essential, with tolerances often below 0.05mm. Traditional methods involved multiple steps like drilling, reaming, and boring, which were inefficient and required skilled adjustments. Seco introduced an integrated solution before and after press-fitting. A combined adjustable precision boring tool and high-precision precifix ensures coaxiality within 0.025mm and IT6 tolerance without separate adjustments. This significantly improves productivity and reduces costs.
After press-fitting, where dimensional accuracy and surface finish are critical, Seco again utilized a composite tool to streamline the process (see Figure 2). The tool features three precision units mounted together, using indexable inserts for cost-effective and accurate machining. The conduit hole can be made with PCD cutters or nanofix reamers, while the valve seat hole uses PCBN inserts. A high-speed steel knife pad and adjustable height and angle settings further enhance both efficiency and accuracy.
Seco's mission is to deliver high-performance products and services through close collaboration with customers, helping them stay competitive. By maintaining open communication and understanding real customer needs, Seco develops optimal tooling solutions that reduce costs and improve efficiency. At every stage, Seco is ready to support customers in achieving their goals, providing timely on-site technical assistance and building long-term partnerships that benefit both parties.
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