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
Cycle time 35-40 seconds including handling
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
Cycle time 35-40 seconds including handling
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
Cycle time 40-50 seconds including handling
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
Cycle time 20-30 seconds including handling
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