Automotive Sub-frame Solution: Integrated PCD Tool for Rough and Finishing Machining

As a critical component of automotive chassis, subframes primarily fall into two categories: iron-based and aluminum-based subframes. For light passenger vehicles with simple structures, high-pressure casting is predominantly employed for subframe fabrication, whereas complex subframes in heavier vehicles such as SUVs typically require low-pressure casting. The primary reason lies in the fact that low-pressure casting allows the use of tubular crossbeam configurations, whereas high-pressure casting cannot accommodate sand cores, making hollow structures challenging to design; thus, U-shaped configurations or reinforcing ribs are employed, or tube sleeves are added in specific areas to create cavity structures. Consequently, both high-pressure and low-pressure aluminum alloy subframe technologies have become mainstream solutions.

Part to be processed: Sub-frame

• Material to be processed: A356-T6

• Machine tool equipment: Vertical machining center

• Cooling method: Internal cooling

• Processing area: Bearing hole

• Product Part Drawings:

Challenges in part machining

1. Due to the small size of the blank holes, the large hole diameters of the workpieces, and substantial machining allowances, chip breakage is difficult to achieve and tool chatter is common. 2. The wall roughness of the workpiece holes must meet requirements ranging from Ra 3.2 to Ra 6.3.

3. The chamfers and arcs on both sides of the product's opening, as well as the reverse end face, are machined on a single tool.

design feature ：

1. The tool tip features a thickened serrated edge to facilitate chip breaking and prevent tool entanglement with chips.

2. To meet the requirement of product hole wall roughness ranging from Ra3.2 to Ra6.3, a micro-adjustable structure with precision-cutting teeth is designed, effectively controlling the cutting conditions and ensuring surface machining quality.

3. The cutting tool is designed as a monolithic unit to enhance its rigidity, ensuring precise machining of hole diameters, fillets on the opposite side of holes, and end faces.

Final Test Results

• Cutting tool diameter: D94.8 •

Speed: S3400 • Feed rate: F1300 • Surface roughness: meets customer requirements

• Chip removal performance: No chip entanglement; excellent chip removal

Xinrui Zhi (Shenzhen) Precision Machinery Co., Ltd. has decades of expertise in the research, development, production, and service of precision tools. Products include standard tools, custom-made tools, and PCD tools. Services cover comprehensive turnkey solutions, tool management services, and tool grinding, helping you overcome technical challenges in machining while reducing costs and improving efficiency.

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