CNC Honda Cylinder Line: Saad Ahmed Khan

CNC Honda Cylinder Line
Saad Ahmed Khan
Time spent 25 days

This presentation discusses machining of CD70
cylinder
Processes in CNC Honda Cylinder Line
Rough Boring
Bottom face turning
Top face turning and diameter
Drilling and chamfering bottom side
Drilling top side
Drilling and spot facing on sides
Finish boring
Rough honing
Finish honing
Inspection
Rough Boring
Matech Vertical Rough boring machine
Cycle time 45-50 seconds including handling
4 insets used on cartridges on boring bar
SNMG 120408/412 for boring
TCMT 11204-24 for facing
Number of pieces produced depending on

hardness of material. 50-75 per inset change
Inset changed or new tip used at start of each
shift
Bore size 46.0mm 0.1, bore position 12mm0.5,
13mm0.5
Vernier used for bore position and dial gauge for
bore size
Bottom facing
CL-15, Chinese DALIAN DALI CNC
CNMG 120408/412 insert. DCBNR2020K12
holder.
Obtuse angle corner of insert used for plane
facing.
Face to face length 62.6mm0.05
Total length 88.5mm0.15
15-20 pieces per insert
Top face and diameter turning

CL-15, Chinese DALIAN DALI CNC
CNMG 120408/412 insert. DCLNR2020K12
Holder.
Obtuse angle corner of insert used for plane
facing.
Acute angle corner of inset used for Diameter
turning. Outer diameter 52.5mm-0.2
Dial gauge for face to face and total height
measurement
Drilling and chamfering bottom side

VDL 1000 machine 1
5 holes
Center drill and chamfer each hole

m7.5 x3
m8 x1
m5.1 x1
m8 reamer
m6 tap on m5.1 hole
Cycle time 790-820 seconds per 10 pieces
Sandvick Golden drill 1000pcs, black drill 24pcs
Hole gauge, counter gauge, vernier for hole
positioning, depth and milling thickness gauging G or
NG
Drilling top side

VDL 1000 machine 2
Carbide drills
M7.5 x3
M8 x1
M9 x1 counter (5mm 0.3)
M6.5 x1
M8 reamer 2 holes 8mm deep + 0.1
Cycle time 875-900 seconds per 12 pieces

Hole gauge, counter gauge, vernier for hole
positioning, depth and milling thickness gauging
G or NG
Drilling and spot facing on sides

VDL 1000 machine 3
Milling 12mm IFE4160

Spot facing 16mm (APXT insert)(800pcs/insert change)
Drill m6.85
Tap m8 (all taps changed once every 24hrs or 800pcs)
Cycle time 180 seconds per 3 pieces including handling
Manual drill and tap
M5 through drill
M6.6 +0.1, 8mm deep counter 0.2
M6 tap both sides
Cycle time 45 seconds including handling
Hole gauge, width gauge, vernier for hole positioning,

depth and milling thickness gauging G or NG
Finish boring
Matech vertical boring machine
3 insets used
CCMT 60204-24
SCMT
TCMT (Chamfering)
100pcs per insert change
Size maintained bore 46.9mm 0.01

Chamfer 2mm deep
Cycle time 50 seconds including handling
Dial gauge for measuring
Rough honing
Matech rough honing vertical
Diamond steel tool stick SD230J60MH4(upto
4000pcs)
Diameter maintained 46.990mm -0.01
Dial Gauge used for measurement
Finish honing
Matech rough honing vertical
600 grit K grade GC abrasive tool stick
GC600K10VGB3 (200-250pcs)
Diameter maintained 47.005 +0.015, ovality
0.005, taper 0.005
Air micrometer used for measurement
Layout CD 70
Rough
Boring
Finish Boring
Rough Honing
CL 15
Manual tap
and drill
Finish Honing
CL 15
VDL1000-3
VDL1000-1
VDL1000-2
Inspection
Production
Rough boring
Cycle time
(seconds)
Available time
(hours)
Production possible
(pieces)
45
560
6.5
520
480
630
6.5
585
540
630
6.5
585
540
315
6.5
292
270
336
6.5
312
288
Matech vertical bore

Bottom facing
40
Cl-15
Top face turning
40
Cl-15
Drilling bottom side
800/10
VDL1000-1
Drilling top side
VDL1000-2
900/12
Drilling and spot facing side
Cycle time
(seconds)
Available time
(hours)
Production possible
(pieces)
180/3
420
6.5
390
360
560
6.5
520
480
504
6.5
468
432
560
6.5
520
480
840
6.5
780
720
VDL1000-3
Drilling and tapping
45
Manual drill and tap

Finish boring
50
Matech vertical bore

Rough honing
45
Matech vertical honing
Finish honing
Matech vertical honing
30
CP data
Finish honing
USL = 47.015, LSL = 47.005
CP = 1.8053, CPu = 1.4671, CPl = 2.1435
Finish boring
USL = 46.910, LSL = 46.890
CP = 6.8150, CPu = 6.6787, CPl = 6.9513
Face to Face CL 15
USL = 62.65, LSL = 62.55
CP = 1.8173, CPu = 1.3569, CPl = 2.2777
Conclusion
VDL1000-1 is bottle neck
Add machine in parallel to increase production
HSE and 5S
Workers advised on safety gear
5S awareness in workers is needed
Workers advised on proper stacking and
movement of cylinders

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CNC Honda Cylinder Line

Saad Ahmed Khan

Time spent 25 days

Processes in CNC Honda Cylinder Line

Number of pieces produced depending on

Top face and diameter turning

Drilling and chamfering bottom side

Center drill and chamfer each hole

Drilling top side

Cycle time 875-900 seconds per 12 pieces

Drilling and spot facing on sides

Milling 12mm IFE4160

Manual drill and tap

Hole gauge, width gauge, vernier for hole positioning,

Size maintained bore 46.9mm 0.01

Matech vertical bore

Drilling and spot facing side

Manual drill and tap

Matech vertical bore

Matech vertical honing

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