With the development of automobile industry and the emergence of new product technology, process, equipment and materials, new challenges are put forward to the cutting tools of new energy Dalian auto parts processing industry. As the most important assembly of the whole vehicle, the weight reduction of the engine is of great significance to the lightweight of the whole vehicle. There are several ways to realize the lightweight of engine: select light materials such as aluminum alloy, magnesium alloy and engineering plastics to replace traditional materials such as gray cast iron; Structural form optimization and lightweight of functional components; Integration or modularization of components with similar functions; Optimize the structure of key parts in the engine, such as crankshaft and connecting rod.

In order to realize the miniaturization and lightweight requirements of the engine, the surface of the aluminum cylinder block adopts the cylinder block spraying technology, and the friction between the piston and the engine cylinder is further reduced by developing the coating process. Instead of using expensive honing machine, boring is carried out in special machining center for automobile instead of honing. In addition, the structural optimization of the engine connecting rod is also very obvious. On the premise of ensuring the strength and rigidity of the workpiece, the rod part to the part around the big head hole has been slimmed down.

Combined hollow camshaft is adopted. The combined hollow camshaft is a cam made of iron-based powder metallurgy material, and then the cam is fixed on the hollow steel pipe by sintering or mechanical method. Compared with cast iron, hollow assembled camshaft has incomparable advantages in reducing mass by 25% ~ 30%, reducing production cost and improving the performance of the whole machine. In addition, 3D printing manufacturing technology provides a new development prospect for internal combustion engine. It enables manufacturers to use layered materials to manufacture parts, reduce assembly operation intensity and optimize the number of engine parts. The benefits of this technology are obvious, even in integrating and optimizing parts.

On the other hand, automobile manufacturing belongs to traditional manufacturing industry. The main development trend of automobile cutting tools is to develop in the direction of high efficiency, precision, flexibility and automation. The first is suitable for high-speed machining, and the realization of high-speed machining involves material and coating technology; Second, it is suitable for hard parts processing, which can simplify the process, save cost and have flexibility; Thirdly, it is suitable for dry machining. Boehringer has been committed to turning for a long time. At present, it has developed turning instead of grinding, which is expected to make a breakthrough in the near future. In the future, there is no need to grind the crankshaft; Dry machining can be realized; The fourth is suitable for compound machining. For example, compound tools are widely used in the machining of new energy motors.

Cylinder bore spraying technology refers to the use of thermal spraying technology (arc spraying or plasma spraying) to spray a layer of alloy coating or other composite materials on the inner wall of the roughened aluminum engine cylinder bore to replace the traditional cast iron cylinder liner. The coated aluminum alloy cylinder block is still an integrated cylinder block, and the thickness of the coating is only 0.3   mm. It has the advantages of reducing the weight of the engine, reducing the friction and wear between the cylinder hole and the piston, improving heat conduction, reducing fuel consumption and CO2 emission. The arc jet process can form many small pores on the working surface of the cylinder, which will store lubricating oil even without honing the anilox groove. The results show that the surface roughness is Ra0 05  μ M-level mirror finish machining can not only improve the anti deflagration performance, but also reduce the friction between cylinder hole and piston.

After the adoption of turbocharging technology, new requirements are put forward for the machining of cylinder head seat ring. The service life of traditional tools is significantly reduced, which does not meet the requirements of high speed and efficiency. Each corner of the new tool is processed by three welded cubic boron nitride blades at one time. The highlight is that there are nine blades in processing, that is, each corner is processed by three blades, which has high processing accuracy, reduced tool adjustment time and simple operation. The new tool can increase the tool life to more than 10 times, adapt to the efficient machining of more than 3 times the feed speed, meet higher machining accuracy and greatly reduce the machining and tool adjustment time.