Machining engines

Supply of fresh air to the engine and removal of combustion gases

Distribution of fuel to the individual injectors

The heart of the engine where all components work in harmony

Transmits the piston force to the crankshaft

The radial force of the pistons is converted into a circular motion

Compression of the intake air for the engine

1. Cylinder head: chip-free/low-chip milling, machining of valve seats, camshaft drillings and injector drillings

Modern cylinder heads made of aluminium alloys are a challenge for machine operators and tool manufacturers both in terms of material and process. Complex tasks such as machining valve seats, camshafts and injectors have to be increasingly process-secure and efficient, as they make up a large proportion of the unit costs. At the same time, precision requirements are becoming more stringent with tighter tolerances and surface specifications.
We respond to this with tool designs that are also user friendly.

1. Boring bar multi-function tool with CBN indexable insert and PCD reamer

Semi-finish and finish machining for valve seat and valve guide on both the intake and exhaust

  • Up to 8-edged full face CBN fixed indexable insert solution
  • PCD reamer up to Z6 for maximum cutting data (carbide also available)
  • No adjustment required thanks to maximum precision (plug & play)
  • Tool system with micrometre-accuracy for maximum process security and repeatability thanks to a special hydraulic clamping system
  • Modular tool structure of standard and semi-standard components (DAH holder, hydraulic adapter, tool holder sleeve, reamer)
  • Runout and angle can be finely re-adjusted on the machine spindle thanks to DAH

2. MaxiMill SEC12 - Milling cutter with suction

Face milling with the suction effect – up to 100% chip-free interiors on the component

  • Uncompromising roughing up to an ap of 8 mm
  • PCD-equipped indexable inserts, robust and yet smooth cutting
  • Extremely long service life above the usual market standard
  • No adjustment required (plug & play)
  • Modular structure of standard components (face mill, indexable insert, milling adapter)
  • Ø 50 mm – Ø 315 mm

3. PCD counterboring tool

Counterboring the core plug hole– up to 100% chip-free interiors on the component

  • 3D-printed chip spoiler for diverting the coolant to the chip and removing chips from the hole
  • PCD with three edges for maximum efficiency
  • Process-secure machining of core plug holes

2. Crankcase: chip-free/low-chip milling, tools for machining cylinder bores, crankshaft bores and mixed materials

Crankcases are currently made from a range of aluminium alloys, which often puts tool manufacturers to the test. When it comes to service life and precision, the cutting material and tool must be designed for maximum performance, especially given the coating technologies, such as wire arc spraying, that are now frequently used in the cylinder bore. 
Our expertise and development work also pay off in terms of reliable and efficient processes when machining mixed materials with one cutting edge, such as in the cylinder and crankshaft bore and on the combustion chamber side.

1. Coolant-controlled boring bar

High-precision finish machining of the cylinder bore

  • Five edges with PCD indexable insert for short process time thanks to accelerated retraction without leaving scores
  • Bore roundness within 0.01 mm
  • Cutting edge compensation for diameter correction (can also be integrated in the machine)
  • Process-secure tool system with accurate repeatability

2. PCD tangential face milling cutter

Uncompromising roughing with high cutting depths and casting burr

  • Tangential PCD indexable inserts with 4 cutting edges and ap up to 11 mm
  • Extremely stable base body and indexable insert design, but still smooth cutting and quiet running
  • Tangential carbide indexable inserts remove large projecting casting burr with ease
  • Maximum service life and efficiency, much greater than the usual market standard
  • Attractive solution for foundries

3. LDS QMill

Milling the microcontour for wire arc spraying (LDS) pre-machining

  • The entire microcontour can be milled in the cylinder bore in just one milling pass
  • High-precision lasered CVD cutting edge on the indexable insert for maximum efficiency and service life
  • Up to three-edged design for short process time
  • Quick and cost-effective re-equipping, as often as you want

3. CNC crankshaft machining

Be it a 12 or three-cylinder engine, without a crankshaft it would grind to a halt. Likewise, when it comes to machining, nothing is possible without a large range of cutting materials and tool systems – after all, the most resistant and therefore challenging materials are used to produce these heavy-duty automotive components. Crankshaft machining goes hand in hand with complex cycle times and extremely variable machining steps, which present a huge challenge for machines, programming and, above all, the tools. Success comes to those who can reliably implement innovative ideas and intelligent tool solutions. 
'We offer innovative cutting material grades, new geometries and tool solutions, which make machining processes more reliable, increase the cutting speed and cutting depth, raise productivity and therefore help to minimise production costs.'

1. Turning chasing of the bearing seat diameter

Turning chasing wheel

  • Handling weight of less than 15 kg
  • Tool change without lifting device
  • Extremely quick tool changeover time
  • Easy handling
  • Cartridge design, flexible, individual
  • Same level of stability as a monotool
  • Comprehensive range of indexable inserts

2. Pin and main bearing milling

Milling wheel

  • High precision milling wheel
  • Max. number of teeth possible
  • X-Lock cartridge system: user friendly, flexible
  • Developed for high cutting speeds
  • Large selection of indexable inserts

3. Deep hole drilling of oil passage bores

Drillmax 24 CSD deep hole drill

  • Straight main cutting edge for low cutting forces
  • TiAlN coating
  • Overall length from 20xD to 30xD
  • Diameter range from 4 to 8 mm
  • Large, smoothly polished chip flutes for secure chip transport
  • High alignment accuracy thanks to 4 guide lands
  • Regrindable

For the turning chasing wheel

  CTCP115 CTCP125 CTCK110 CTCK120

For the milling wheel

Steel crankshafts - ISO P Cast iron crankshafts - ISO K
1112 (ISO P30) 1122 (ISO K20)
CTPP225 (ISO P20 - P30) CTPK220 (ISO K15 - K25)
CTPP235 (ISO P35)  

4. Machining common rail

Highly efficient common rail injection systems are an essential component of modern engines, designed to reduce consumption and emissions. The fuel rails release the pressure evenly across all the components that make up the high-pressure system. The load on these components is extremely high, so state-of-the-art, difficult-to-machine materials are needed. 
Thanks to our extensive range of tools and expertise, the pressure in the machine shop is also evenly spread: Machining there is as efficient as the latest generation of engines.

1. Multi-purpose over turning tool

Over turning and countersinking the fuel line connection

  • Three-edged, smooth cutting indexable insert
  • Turning, face milling and countersinking with just one tool
  • Fewer tool changes
  • Long service life and high efficiency thanks to multi-purpose solution

2.Thread milling tool

External thread milling on the pressure pipe connections

  • Reduction in the machining time through 4 thread profile indexable inserts
  • High tool stability enables high cutting speeds and therefore shortens the process time
  • Indexable insert can be quickly changed with no adjustment required (Plug & Play)
  • Very short, manageable chips
  • Perfect cutting-edge cooling thanks to through coolant supply, resulting in a longer tool life
  • Thread profile indexable inserts can be reground

3. MGF HPC thread milling cutter

Thread milling the connection thread

  • Process-secure thread milling with accurate repeatability
  • Reduction in the process time compared to conventional threading
  • Eight cutting edges for maximum cutting speeds and efficiency
  • Thread depth down to the bottom of the hole possible
  • The same tool can be used on different materials (steel up to a tensile strength of 1,200 N/mm², stainless steels, cast iron materials, titanium alloys)
  • Very short, manageable chips
  • M4 – M20 available in 1.5xD and 2xD from stock
  • M4x0.5 – M16x1.5 available in 1.5xD and 2xD from stock

5. Machining connecting rod

The connecting rod connects the piston and the crankshaft and converts the linear upward and downward motion of the piston into the circular motion of the crankshaft. Unsurprisingly, it is subjected to unrelenting tension, pressure, bending and torsion. Microalloyed or carbon-manganese steels, which are processed using a drop forging method, ensure that connecting rods can withstand such permanent stress when the engine is running. 
For these kinds of materials, which are being steadily refined, vast expertise in tool systems and cutting materials is needed – such as that offered by our skilled team.

1. Snap-on tool for tilt drill head

Big end finish machining

  • Stable four-edge Quatron indexable insert
  • Outstanding drilling quality with no retraction scoring
  • Long service life and high efficiency

2. Tilt drill head

High-precision finishing for the big and small end

  • Micrometre-precise adjustment
  • Tilt-adjustment mechanism is automatically triggered in the tool through the feed and return motion of the machine drawbar
  • Cutting stroke/drawbar stroke 1:85
  • Maximum process security with tight tolerances
  • 100% balanced tool system
  • Snap-on tool adapter with HSK and ABS

3. Multi-purpose tool

Solid drilling, counterboring of the big and small end including chamfering in a single operation

  • Stable four-edge Quatron indexable insert
  • Suitable for difficult conditions, such as casting drafts, mill scale and interrupted cut
  • Fewer tool changes
  • Long service life and high efficiency thanks to multi-purpose solution
  • Solid drilling and counterboring tool in one

6. Milling and grooving/turning turbocharger

Turbochargers are a common component in modern vehicles as they offer greater efficiency than their naturally aspirated counterparts, whilst also helping to lower emissions. However, these advantages come at the expense of a challenging machining process. On the exhaust side, high-alloy, heat-resistant materials with a high level of nickel and chromium or cast iron are used. Both materials are either extremely abrasive or result in very high temperatures in the machining zone – neither of which are economical conditions for tools. Yet thanks to clever interpolation turning, circular milling strategies and combined 4-in-1 tool systems, machining times are reduced and precision is ramped up – production is also turbocharged. 

1. Boring bar

Finishing the V-belt with interpolation recess turning

  • Extremely sturdy tool design
  • Cutting edge geometry adapted to the machining process
  • Through coolant supply directly at the cutting edge
  • Turning operation can be performed on the machining centre thanks to circular motion of two linear axes
  • Coated solid carbide grades, specially developed for machining nickel-based alloys

2. KOMtronic U-Axis system

Complete finishing of the V-belt side

  • Time savings of up to 67%
  • Up to 25% faster machining
  • One tool instead of four
  • Better surfaces and greater accuracy of form
  • Integrated micrometre-precise path measurement system for ultimate precision
  • 3D-printed snap-on tools can be used, which are perfectly suited to the process
  • The U-axis system has an extremely long service life with a maintenance and repair service

3. MaxiMill 275 - the face milling cutter for high-alloy stainless steels

Specially developed for turbocharger machining

  • Robust design, stable seat in the base body
  • Octagonal indexable inserts with 16 usable cutting edges
  • Special cutting material designed for maximum thermo-mechanical loads
  • Defined, stable cutting edge guide
  • Ensures maximum productivity, process security and efficiency
  • Available in diameters ranging from 63 – 125 mm as standard