Simultaneous Machining of a Material Combination with an Internally and Externally Cooled Cutting Insert

This paper discusses the machining of cylinder running faces of aluminum engine blocks with reinforced, arc-sprayed cylinder walls. Such special material combinations and, therefore, processing conditions are common in the automotive sector, where the load-oriented material use induces a significant reduction of fuel consumption. The machining of such a material combination comes along with several challenges including notch wear on the main cutting edge as a result of the arc-sprayed cylinder walls or a built-up edge formation on the main cutting edge because of the aluminum. Promising approaches by means of an internally and externally cooled cutting insert are presented in this paper and compared to common external cooling.