Aluminium wheels - valve holes

Description

Our customer from Germany produces approx. 800‘000 aluminium wheels for cars per year, among others also for the premium brands.

The customer was looking for a solution to produce the valve hole more cost effective. He wanted to have it done in a single pass and without requiring the work piece to be turned.

Application Details

Application Details

  • Valve hole Ø11.6mm
  • Countersink forward Ø16.25mm
  • Chamfer backward Ø13.1mm x 90º
  • Material Aluminium ALMg3Si7.

The production lines have used emulsion as a coolant so far. The new lines will be equipped with microlubrication (minimum quantity lubrication) only.

Valve hole: Forward machining

Valve hole: Backward machining

Proposed Solution

Proposed Solution

The solution from HEULE is a VEX-S Combi-Drilling-Chamfering-Tool which has been tailored to the specific needs of the customer. The tool is capable to machine the 3 form elements in one operation and without further tool changes.

The deburring at the back is carried out by the prove SNAP function priniciple whereas indexable inserts made of carbide are applied for the shaped chamfer at the the front side of the bore.

Machining parameters:
Drilling and countersinking forward:
Speed 2750 rpm, Cutting speed vc 100 m/min,
Feed 0.2 mm/rev.

Chamfering backward:
Speed 2750 rpm, Cutting speed vc 115 m/min,
Feed 0.15 mm/rev.

Customer Benefits

Customer Benefits

So far, the valve holes have been produced by stepped drills. Then, the bore ø11.6 on the back has been deburred manually because of the insufficient accessabilty at the backside. According to the customer, the resharpening of the stepped drill has been very complicated and time-consuming.

Customer Satisfaction

Customer Satisfaction

The customer is very pleased by the reached result and production time.
The new solution eliminates the manual deburring operation. The bore is manufactured completely and process capable by machine. The blades can be replaced easily  and without readjustment of the machine.