The cylinder is a critical component of the automobile engine, serving as a central connection point for various parts and exhaust systems. It ensures that all components remain properly aligned and move in coordination. The cylinder block, being a complex and precisely cast part, requires high dimensional and positional accuracy. Machining such a workpiece is challenging, especially with traditional machine tools, which often result in poor precision and low efficiency. Operator skill and machining errors further complicate the process. To address these challenges, users have demanded fully automatic processing solutions for mass production of cylinder parts.
Our VMC2180s vertical machining center is designed to handle high-precision parts like plates, discs, housings, and molds with complex shapes and multiple processes. It supports continuous milling, drilling, expansion, boring, tapping, and precise machining of 2D and 3D curved surfaces and bevels. By reducing the production cycle and replacing three conventional machines with one, it significantly improves efficiency and delivers excellent economic benefits to users.
To meet the requirements for fully automatic machining of engine blocks and enhance productivity, the clamping system must also be automated. One specific user requirement involves machining the top surface of the engine block, which measures 1062mm × 260mm. This necessitates a face mill with a diameter of at least 260mm. In practice, a φ315mm wiper face mill was used (see Figure 2), but this large tool exceeds the capabilities of the VMC2180s in terms of size and weight. The machine’s tool magazine holds up to 32 tools, with a maximum cutter diameter of 125mm, a tool length of 400mm, and a maximum weight of 20kg. The selected tool, with a diameter of 315mm, length of 340mm, and weight of 31.6kg, cannot be automatically changed on the machine.
To solve this issue, we implemented a custom solution. A milling cutter holder was placed on the left side of the worktable, while a fully automatic positioning and clamping fixture was installed on the right (see Figure 3). The fixture uses two holes on the bottom surface of the engine block for positioning, similar to a "one pin, two pins" method. It also clamps the sides of the cylinder body, allowing for precise machining of the top surface and associated holes.
The fixture includes an automatic hydraulic clamping system. When the workpiece is placed on the support plate along the guide rails, the pre-positioning device ensures accurate placement. Upon pressing the clamping button, the hydraulic cylinder pushes the cylinder block toward a non-contact switch, which signals the machine to retract. The system then engages the positioning pin and clamps the workpiece automatically, eliminating manual intervention.
For the large face mill, the tool holder is fixed on the left side of the table. A check rod is installed on the tool holder, and a probe is mounted on the spindle to locate the center of the rod. This position is recorded in the machine coordinate system, allowing the tool to be programmed like any other. During machining, the spindle retrieves the appropriate tool from the holder, enabling full automation of the tool change process for large cutters.
In conclusion, by integrating the VMC2180s machining center with an automatic hydraulic clamp and a specialized tool holder, the entire cylinder processing workflow becomes fully automated. No manual intervention is needed, ensuring reliable positioning and safe, fast clamping. This approach greatly enhances productivity and achieves a high level of automation and information integration in the manufacturing process.
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