crankshaft machining - ffg- · pdf filetechnology into a standard crankshaft machining cell...
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CRANKSHAFT MACHINING
Solutions & Applications, Turning
, Milling
, Hobbing
, Grinding
, Honing
, Composites
, Systems Integration
, Automation & Software
, Services
, Tooling & Fluids
, Core Components
Crankshaft MachiningOur Expertise
02 | 03
The comprehensive range of equipment offered by MAG is designed to
perform most all of the rough-end operations on small car to large size
truck crankshafts, regardless whether these crankshafts are made of
cast iron or forged steel. Modular subassemblies, identical control and
drive concepts, as well as standardized HMIs significantly ease your daily
workload.
With over 90 years of experience in crankshaft machining, we provide
various levels of turnkey solutions, all precisely tailored to your specific
workpiece and individual needs. We accommodate challenging product
designs, production rates and flexibility requirements. Our focus targets all
parameters critical to successful manufacturing, such as workpiece quality,
process reliability, machine uptime, part piece and life cycle costs.
We challenge you to benefit from our vast experiences and to partner-up
with MAG for your next crankshaft program.
Part Range Crankshafts for
, For small cars / motorcycles
, Full to large size cars
, Light-duty trucks
, Medium to heavy duty trucks
, Other sizes / applicators on request
Your Advantage
, Uniform machine concept for the entire rough-end section
of the crankshaft line
, Our entire system and process know-how
, Single-source contact and responsibility for the entire supply content
, Uniform control and drive concepts for all machines
, Operator-friendly HMIs with communicative screen pictures tailored
specifically to crankshaft manufacturing, resulting in significantly
simplified machine operation
, Standardized subassemblies for quick and cost-effective maintenance,
as well as reduced spare parts inventory
, Broad product and technology spectrum delivering best-practice
approach for all applications
Technologies
, Cutting to length and centering
, Oil hole drilling
, Turning
, Roller burnishing
, Turn-turnbroaching
, High-speed external milling
, Hyper speed milling
Truck Competence
Requirements
, From small to mid-sized to large batches
, High surface qualities
, High cutting performance
Our Solution
, Indiviual machine generation for truck crankshafts
, Especially robust machine design
, Processing with two independent steady rests possible
, Special tooling and processing concepts
, Experience with imbalanced V shafts
, Processing of center and pin bearings in one setup
Your Advantages
, Productivity
, High flexibility
, Environmentally friendly
Demanding Applications for Heavy Industry
Industries
, Pump shafts
, Ship engine components
, Oil field crankshafts
, Off road
, Locomotives
, Stationary engines
, Compressor shafts
, Crankshafts up to 6 meters long
Industrial Requirements
, Small batch production
, Large and heavy parts
, Many different varieties
Our Solution
, A high degree of flexibility
, Multifunctional machines
, High stability
, Integration of multiple technologies
(turning, milling, drilling)
, Efficient production of prototypes
and small batches
Your Advantages
, Flexible machine concept
, Robust machines
, Different sizes
, Workpiece-related engineering
04 | 05
Cutting to Length and Centering / End Machining
Utilizing rigid workspindles on both sides, the initial processing step quickly
mills the crankshaft to proper overall length. Oversized on purpose, the
machine is fully capable of handling large material stock and parting line
conditions. Subsequent to the facing task, center holes are then bored to
provide the reference and datum points for all subsequent machining
operations. Optionally, the machine can also perform hollow milling of
oil seal and postend diameters to form clamping surfaces for following
operations. Of course, most of these tasks are being done on both
crankshaft ends simultaneously, giving our machine concept a distinctive
production rate advantage. Precise clamping and alignment units ensure
compensation for stock and imbalance conditions.
Machining Options
, Cutting to length and centering
, Mass-centering, if interfaced to a balancing machine
, Hollow-milling of clamping diameters on oil seal and postend diameters
Your Advantage
, Precise pre-machining provides a solid basis for down-stream operations
, Uniform and simple machine concept
, Short cycle times due to simultaneous machining on both part ends
, Time-proven MAG standard machine concept
, Machine design optimized for size and inline layout
, Machine configuration and footprint uniform with oil hole drilling, turning
and roller burnishing machine
Oil Hole Drilling
The two drilling heads operate synchronized but fully independent of
each in B-axis and Y-axis direction to perform oil hole drilling tasks on a
horizontally chucked crankshaft. Each machining head uses its own tool
change rack, enabling the machine to produce virtually every oil hole
configuration at the shortest possible cycle time.
State-of-the-art drill bit technology combined with a proven MQL system
for optimized productivity and extended tool life times. The horizontally
arranged single-part concept allows for utilization of simple and economic
workpiece handling equipment.
Special solution: Both technologies oil hole drilling and roller burnishing
can be combined in one machine.
Your Advantage:
, Fully flexible tool change capability allowing for one unit in operation
at all times
, Simple machining process, conventional drilling instead of deep
hole drilling
, MQL system for optimized production rate and tool life
, Time-proven MAG standard machine concept
, Machine design optimized for size and inline layout
, Machine configuration and footprint uniform with cutting to/centering,
turning and roller burnishing machine
Cutting to length and centering Oil hole drilling
Our Technology Newcomers
04 | 05
Turning low end Roller burnishing of thrust bearing
CNC Turning
Turning is an ideal process for machining of various concentric features,
such as: flange and postend areas, counterweight topping, thrust bearing
faces and reluctor ring diameters or mounting surfaces.
Our special crankshaft turning cells offer the inherent flexibility to be
equipped in accordance with the respective operation sequence, machining
task and associated requirements. The available machine spectrum ranges
from 2-axis to 4-axis configurations to achieve the most cost-effective
solution for the specific application. For boring and milling applications,
including Woodruff keyways and timing notches, the special crankshaft-
turning cells can be equipped with a variety of driven tool options.
Your Advantage
, Simple machine concept with the flexibility of a multi-function
turning center
, Cost-effective machine design
, Time-proven MAG standard machine concept
, Machine design optimized for size and inline layout
, Machine configuration and footprint uniform with cutting to
length/centering, oil hole drilling and roller burnishing machine
Roller Burnishing
Roller burnishing can substitute machining of thrust wall faces by hardening,
grinding and super finishing. The process initiates by measuring the lateral
position of the previously processed thrust wall faces inside the machine,
utilizing a touch trigger probe system. Thereafter, the thrust walls are
precision turned and subsequently roller burnished.
The purpose-made burnishing tool uses controlled pressure applied via
rollers to compress the material on the surface of the thrust wall faces.
The result is a compacted surface with increased hardness and much
smoother finish quality, providing a significant improvement of the bearing
contact area. Our cost-effective integration of the roller burnishing
technology into a standard crankshaft machining cell allows to combine
other finishing tasks, such as turning of the flywheel pilot diameter,
postend and reluctor ring features into a flexible multi-task operation.
Special solution:
Both technologies oil hole drilling and roller burnishing can be combined
in one machine.
Your Advantage
, Cost-effective machining process, highly accurate
, Flexible machine concept with high degree of utilization,
due to the underlying presence of a CNC turning machine
, Time-proven MAG standard machine concept
, Machine design optimized for size and inline layout
, Machine configuration and footprint uniform with cutting
to length/centering, oil hole drilling and turning machine
Bearbeitung des PasslagersÜberdrehen des Zapfens
06 | 07
Turn-Turnbroaching
Turn-turnbroaching is a combination of radial plunge cutting for roughing
and rotary broaching for finish machining. The tool cartridges are arranged
on the outer circumference of the tool disc and engage in material removal
action according to the process sequence. The large quantity of available
cartridges allows for redundant tool capacity and consequently an optimized
tool life strategy.
The broaching heads feature CNC-controlled vertical, horizontal and rotary axis
capability. This allows for utilization of the same cutting tool configuration for
various crankshaft types with different bearing dimensions. Flexibility, high
machining accuracy and short cycle times are the most significant
advantages of the turn-turnbroaching technology.
MAG turn-turnbroaching machines are used for machining of main bearing
and crankpin journals on small size crankshafts. Crankshafts for medium
to large size cars, as well as truck size applications, consist primarily of
machining of concentric features, such as main bearing journals, which is
often expanded to flange and postend areas.
Your Advantage
, High process flexibility
, High machining accuracy
, Short cycle times / high productivity
, Complete machining of all concentric crankshaft features in
a single-setup
, Machine configuration and footprint uniform with high-speed
external milling
Tandem-Disc Turn-Turnbroaching
The twin tandem disc process demonstrates the flexibility and basic rigidity
of the MAG turn-turnbroaching machine more thoroughly than any other
comparison would be able to. Rough machining of four main bearing
journals simultaneously allows for unparalleled production increases.
Want more? Tandem-disc turn-turnbroaching combines the salient
advantages of rotary broaching and turn-turnbroaching for a process that
delivers high productivity and tight tolerances.
Our Technology Classics
Turn-turnbroaching
High-speed external milling
High-Speed External Milling
H-S external milling provides better process flexibility, shorter cycle times
and higher accuracy. The increase in workpiece quality results from low
cutting forces and consequently smaller workpiece deflection, as well as
the ability to produce less machining heat and to discharge of the present
heat far quicker and more efficiently into the metal chips and away from the
tool, workpiece and machine. The MAG H-S external milling process rotates
a concentrically clamped workpiece at low speed. All machined surfaces
are produced by CNC controlled milling heads moving independently, but
fully synchronized to the angular position of the workpiece, i.e. in a „chase-
the-pin“ mode. Most commonly, H-S external milling is used for machining
of crankshaft pin journals, where it offers the convenience of parameter
programmable stroke and index positions.
Other preferred applications include machining of main bearing journals,
counterweight diameters and reluctor ring mounting surfaces on crankshafts,
as well as lobes on medium to large size camshafts. H-S external milling
has the ability to really take advantage of lower material stock conditions, as
more commonly seen today on small car to medium truck size crankshafts.
Your Advantage
, High workpiece quality due to low cutting forces and efficient
discharge of cutting heat
, High process and change-over flexibility
, Simple machine concept with reserves to take advantage of
future tool developments
, Allows for simple workholding arrangements
, Short cycle times / high productivity
, High machine availability due to shorter tool change times,
but longer intervals
, Machine configuration and footprint uniform with turn-turnbroaching
14 | 15
New Process of Hyper Speed Milling
MAG meets the industry demand for efficient production.
In collaboration with a tool manufacturer, we have developed an outstanding
cutting inserts quality which enables our customers to significantly reduce
the processing time required to mill crankshafts.
This is Possible Because
, The design and performance of our machines are the basis for the
extraordinary increase of cutting speeds
, Our milling supports ensure a smooth and safe turn to achieve the
required surface qualities
, Strong drives ensure these high cutting speeds which reduce
processing time
Your Advantages
, Increased efficiency by reduced processing times
, Sustained high quality
, New technology can be integrated within existing series
New Technologies
08 | 09
Motorcycles and Small Full to Large Size Cars Medium to Heavy Duty Trucks
Applications to Medium Size Cars and Light Duty Trucks and Off-Highway Engines
Cutting to length and centering CE series CE series
Turning VDF T series VDF T series VDF T series
Turn-turnbroaching CB series CB series CB series
High-speed external milling CM series CM series CM series
Oil hole drilling CD series CD series
Precision turning and burnishing of thrust walls VDF T series VDF T series
Product LineFields of Application
Our Range of Applications
4-Cylinder Automotive Cast Iron Crankshaft
1. Cutting to length and centering
Machining Task Machine Type
CE series
2. Rough/semi-finishing of flange,
postend and main bearing journals
3. Rough/semi-finishing
of crankpin journals
4. Oil hole drilling
5. Finish machining of thrust walls
CB series
CM series
CD series
VDF T series
10 | 11
6-Cylinder Automotive Steel Crankshaft
1. Cutting to length and centering,
pre-machining postend
3. Semi-finishing of flange, postend
and main bearing journals
4. Semi-finishing of crankpin journals
5. Oil hole drilling
6. Finish machining of thrust walls
2. Rough machining of main
bearing and crankpin journals,
with counterweight topping
Machine Type
CE series
CM series
CB series
CM series
VDF T series
CD series
Machining Task
12 | 13
We offer TurnKey Solutions
1. Inquiry / Concept Phase
We provide you with an initial concept of a recommended manufacturing
process and production line arrangement, all tailored to your specific
crankshaft and requirements. The level of detail work included in the initial
concept already includes process sheets, identification of machine type,
machine count and outline of purchased equipment.
Your Advantage
, Utilization of best-practice approach combined with our crankshaft
machining experience right from the start of the concept design phase
, Selection of key-partners and sub-suppliers based on the specific
program requirements and product design
, Single-point contact for all concerns of the program
, Quick implementation time
2. Engineering/Design Phase
MAG provides advanced planning of the entire manufacturing system. We
furnish the machining know-how for our own delivery content, as well as
for all operations and equipment provided by sub-suppliers.
Selection of the final process concept is done together with you and the
key-partners as part of the simultaneous engineering tasks.
Your Advantage:
, Centralized project planing results in fewer interfaces –
You communicate with only one partner
, Only minimal planning and engineering efforts from your side
, All elements of the manufacturing system are matched and
coordinated by us
, Know-how transfer materializes already during the engineering phase
Clear interface with graphic support
1
1
= MAG machines
3. Preacceptance
Verification of the machine and process capability is done at the
respective manufacturer’s location together with you. This includes machine
setup, verification runs, part inspection and statistical evaluation of results.
Your Advantage
, Capability behavior is inspected and reviewed at the respective
manufacturer’s site already
, Optimizations are performed in cooperation with you
4. Installation and Commissioning
Installation and commissioning supervision is provided by our own personnel
together with staff from the respective machine manufacturers. Generally,
we employ the same people for the preshipment tests, as well as final
machine installation. Project management responsibility lays with us.
Your Advantage
, Shorter installation times, due to utilization of experienced personnel with
prior exposure to the respective machine equipment and applications
, Onsite project management with single-point contact for you
5. Drilling and chamfering all oilholes
4. Turning and burnishing thrust walls, turning mounting face and gearringseat, including main bearing 1
3. Milling pins with undercuts, topping counterweights
2. Turn-turnbroaching mains, pre-turning faces of flange and reluctorring seat
1. Cutting to length and centering, turning outer diameter flange and stub end
5. Final Acceptance
Machine and system capability runs, data collection and evaluation of
results. Final acceptance provides the proof that the process, machines
and entire manufacturing system are capable at the final installation site
in respect to quality and throughput requirements. Upon final acceptance,
ownership of the manufacturing system is transferred to the customer
and his staff.
Your Advantage
, Machine and system capability verification and demonstration at final
installation site under the management of MAG
, Owner-ship transfer of a fully functional and verified manufacturing
system to you and your personnel
6. Ramp-up Support and Training
All the way through the production launch, ramp-up and optimization phase,
MAG’s onsite staff ensures a seamless transition of ownership and
responsibilities. We provide classroom and on-the-job training and enable
the necessary know-how transfer through subsequent production support
services. Upon request, MAG is prepared to provide you with further support
services based on the applicable requirements.
Your Advantage
, Short ramp-up time
, Ongoing know-how transfer
, Onsite troubleshooting resources for quick reaction time during the
production start and subsequent ramp-up phase
14 | 15
Service and Support
Original Spare Parts
, 24/7 Spare Parts Service
, Spare Parts Package
, Central Warehouse
, MAG Fluids
Spindle Service
, Repair / Overhaul
, Loop Programs / Exchange Spindles
The services team at MAG is your single source for maintenance and productivity solutions designed to optimize plant operations. Through
comprehensive support and factory-direct expertise, manufacturers achieve maximum equipment availability and utilization reducing their cost
per piece. By providing a proven and innovative service and support program, our customers maintain the lowest possible total cost of ownership
of capital equipment throughout the machine’s life cycle.
Service
, Service Hotline / 24/7 Support
, Repair Service
, Maintenance
, Machine Certification and Inspection
, Rebuild
, Retrofit
, Used Machines
, Machine Relocation
, Service Contracts
Engineered Services
, Process and Production Optimization
, Complete Care Packages
, Technology Integration
Training
, Operator Training
, Fluid Training
, Maintenance Training
, Interactive Training
, Programming Training
Software
, Machine Data Acquisition
, Machine Diagnosis
, Condition Monitoring
, Energy Management
, Virtual Machine
MAG IAS GmbH
Location Göppingen
Stuttgarter Straße 50
73033 Göppingen
Germany
tel +49 71 61 201-0
fax +49 71 61 201-353
w w w. m a g - i a s . c o mThe machines shown are examples. Actual machines may vary based on selected options.T7002(01DE)en/500/09.12
Solutions & Applications, Turning
, Milling
, Hobbing
, Grinding
, Honing
, Composites
, Systems Integration
, Automation & Software
, Services
, Tooling & Fluids
, Core Components
MAG is a leading machine tool and systems company serving the durable
goods industry worldwide with complete manufacturing solutions for metal
cutting and composites applications. With a strong foundation based upon
renowned brands such as Boehringer, Cincinnati, Cross Hüller, Ex-Cell-O,
Fadal, Giddings & Lewis, Hessapp, Honsberg, Hüller Hille and Witzig & Frank,
MAG is recognized as the preeminent provider of tailored production solutions
based on state-of-the-art technology. Key industrial markets served include
aerospace, automotive and truck, heavy equipment, oil and gas, rail, solar energy,
wind turbine production and general machining.
With manufacturing and support operations strategically located worldwide,
MAG offers comprehensive lines of equipment and technologies including
turning, milling, hobbing, grinding, honing, systems integration, composites
processing, maintenance, automation and software, tooling and fluids, and
core components.