Aoshiji® Custom Tool – Solid Carbide Drill-Reamer Combination Tool for Diesel Engine Cylinder Block Machining
In this case study, we present Aoshiji® Custom Tool’s solid carbide drill reamer combination tool for diesel engine cylinder block machining, integrating drilling and reaming in a single high-efficiency solution.
A diesel engine is an internal combustion engine that compresses air to high temperatures, causing injected diesel fuel to self-ignite and drive the piston. Known for its high efficiency, durability, and strong torque, it is widely used across transportation, construction, and power generation industries. With continuous technological progress, modern diesel engines are becoming more environmentally friendly and intelligent.
1. Working Principle
Intake stroke: The piston moves downward, drawing air into the cylinder.
Compression stroke: The piston moves upward, compressing air to a high temperature.
Power stroke: Diesel fuel is injected, self-ignites, and forces the piston downward.
Exhaust stroke: The piston moves upward again, expelling exhaust gases.
2. Key Features
High thermal efficiency and excellent fuel economy
Strong torque output, ideal for heavy-duty and low-speed operations
Exceptional durability and low maintenance cost
3. Applications
Transportation: Trucks, buses, ships, and locomotives
Construction machinery: Excavators, bulldozers, and cranes
Power generation: Backup and primary diesel generators
Agricultural equipment: Tractors and harvesters
4. Development Trends
Environmental protection: Use of SCR and DPF systems to reduce emissions
Efficiency improvement: Enhanced combustion and reduced fuel consumption
Intelligent control: Integration of electronic systems for better performance
Workpiece: Diesel Engine Cylinder Block
Material: HT280 (High-Strength Gray Cast Iron)
Machine Tool: Horizontal Machining Center
Cooling Method: Internal Coolant (Emulsion)
Machining Area:
Cross water hole drilling — Ø22 mm × 80 mm depth
Ø29 mm hole × 15 mm depth with 2.25 × 20° chamfer
Tool Life Requirement: 2,000 – 2,500 pieces
The customer’s on-site machining equipment is relatively outdated, and the overall working conditions are not ideal — posing significant challenges to the cutting performance and stability of the tool.
To improve production efficiency, the customer required the original machining cycle time of 26 seconds to be reduced to 19 seconds, representing a 24% reduction. At the same time, the tool’s performance and life expectancy were required to remain unchanged — a demanding test for process optimization and tool design.
The customer maintained strict cost control requirements, insisting that the carbide drill reamer must achieve the specified tool life target without compromising consistency or quality.
04 Solid Carbide Drill Reamer Combination Tool Solution by Aoshiji® Custom Tool
Design Features
The solid carbide drill reamer combination tool from Aoshiji® Custom Tool integrates both drilling and reaming functions into one tool, significantly enhancing machining efficiency, accuracy, and overall productivity — making it ideal for diesel engine cylinder block applications.
Key Advantages:
High Efficiency: Combines drilling and reaming in a single operation, reducing tool changes and cycle time.
High Precision: Ensures consistent hole diameter, roundness, and superior surface finish.
Cost-Effective: Reduces tool inventory and tool-change frequency, lowering overall tooling costs by 52%.
Versatile Application: Suitable for a wide range of materials, including steel, cast iron, and aluminum alloys.
| Tool Brand | Tool Diameter | Cutting Speed (Vc) | Spindle Speed (S) | Feed Rate (F) | Tool Life |
|---|---|---|---|---|---|
| Other Brand | D22 / D29 / D32 | 76 m/min | 1,100 r/min | 250 mm/min | 2,000–2,500 pcs |
| Aoshiji® Custom Tool | D22 / D29 / D32 | 76 m/min | 1,100 r/min | 250 mm/min | 3,000 pcs (+24% efficiency, +50% tool life, −52% tool cost) |
| Conclusion | Aoshiji® Custom Tool improved cutting efficiency by 24%, extended tool life by 50%, and reduced tooling cost by 52%, ensuring stable performance and superior cost-effectiveness in mass production. | ||||
The solid carbide drill reamer combination tool developed by Aoshiji® Custom Tool has proven highly effective in addressing the customer’s machining challenges in diesel engine cylinder block production. It maintains consistent dimensional accuracy even under unstable or aging machining conditions, ensuring reliable hole quality throughout extended production cycles.
Thanks to its integrated design, the solid carbide drill reamer combination tool supports high-volume manufacturing by combining drilling and reaming in one step. This reduces cycle time, improves stability, and ensures both precision and process efficiency in demanding diesel engine machining environments.
In conclusion, the solid carbide drill-reamer combination tool provides the customer with a robust, high-performance machining solution—achieving stable precision, longer tool life, and improved productivity even when operating under limited rigidity and suboptimal coolant conditions.
As outlined in our previous article “Tech Insights | Three Methods for Machining Superhard Cutting Tools – Advantages of Laser Processing in PCD Tool Manufacturing Featuring PCD Keyseat Cutter with Shank | Aoshiji® Custom Tool”, we continue to focus on engineering tools that deliver measurable performance gains in demanding environments. For this project, the customer required a 24% reduction in cycle time—from 26 seconds to 19 seconds—without sacrificing accuracy or tool life. Through the integration of drilling and reaming functions into a single solid carbide tool, we achieved both productivity improvement and process reliability.
Our drill-reamer combination design allows a single pass to complete both operations, ensuring:
High efficiency – eliminates tool changes and reduces idle time;
High precision – maintains hole dimensional accuracy and surface finish;
Cost-effectiveness – reduces tool count and tool change frequency, cutting overall tooling cost by up to 52%;
Material versatility – applicable to steel, cast iron, and aluminum alloys.
To support similar applications, Aoshiji® Custom Tool also provides the Step Reamers – Solid Carbide & PCD Custom CNC Tools for multi-diameter hole machining and the Combination Drill & Chamfer Toolfor high-efficiency drilling and chamfering integration.
Just as global leaders like Sandvik Coromant and MAPAL continue to set the benchmark in engine component machining, Aoshiji® Custom Tool remains committed to delivering advanced, high-efficiency, and precision-engineered solutions that balance speed, accuracy, and cost.
By choosing Aoshiji® Custom Tool’s solid carbide drill-reamer combination tools, manufacturers gain not only higher productivity and tool life but also a proven, cost-optimized solution that ensures machining consistency across even the most demanding production environments.
