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Machining engines

1. Cylinder head

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

4. Fuel rail

Distribution of fuel to the individual injectors

2. Crankcase

The heart of the engine where all components work in harmony

5. Connecting rod

Transmits the piston force to the crankshaft

3. Crankshaft

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

6. Turbocharger

Compression of the intake air for the engine

         

1. Cylinder head machining:
Our tools turn heads

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.

The CERATIZIT Group responds to this with tool designs that are also user friendly.

1. MaxiMill SEC12

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 insert, robust and yet smooth cutting
  • Extremely long service life above the usual market standard
  • No adjustment required thanks to maximum precision (plug & play)
  • Modular structure of standard components (face mill, indexable insert, milling adapter)
  • Standard diameters 50 mm – 160 mm
To product

2. Semi multi-purpose tool and Finish multi-purpose tool

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

  • Three-edged full face CBN fixed indexable insert solution
  • Solid carbide pilot reamer up to Z8 for maximum cutting data (also available in PCD)
  • Solid carbide reamer up to Z8 for maximum cutting data (also available in PCD)
  • 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, blade carrier, indexable insert, reamer)
  • Runout and angle can be finely re-adjusted on the machine spindle thanks to DAH

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 machining:
We're on the case at the heart of the engine

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.

The expertise and development work by the CERATIZIT Group 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. Roughing boring bar

Rough machining the cylinder bore

  • Cut distribution over 4+4 teeth to distribute the allowance and reduce the cutting force
  • Four effective teeth for maximum efficiency
  • Optional accessory: vibration damper to reduce vibrations during the machining process
  • PCD performance plates with chip breaker for large cutting depths, controlled short chips and long service life

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. 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
  • Defined surface roughness if required

         

3. Crankshaft machining
Tools that are a stroke of genius

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.

The CERATIZIT Group offers 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 wheel

Turning chasing of the bearing seat diameter

  • 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. Boring bar

Grinding and chamfering the journal (control side)

  • Short machining time for grinding and chamfering with a
    single tool
  • Sturdy indexable inserts with wide range of insert shapes
    and geometries
  • Wide selection of steel and cast iron indexable inserts

3. Special MaxiMill A273

Face milling and centring the flange (gearbox side)

  • Face milling cutter including centre drill
  • Combines the cut-to-length process with centring
  • 16 usable cutting edges for maximum efficiency
  • CERAsmart detector for visual service life monitoring of the centre drill (milling inserts via machine control system)
  • Wide selection of steel and cast iron inserts

         

4. Fuel rail machining
Take the pressure off: High-end machining for short process cycles

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 cutting-edge, difficult-to-machine materials are needed.

Thanks to the extensive range of tools and the expertise of the CERATIZIT Group, the pressure in the machining halls 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 thro' coolant supply, resulting in a longer service 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. Connecting rod machining
Hot rod your process! Fewer tool changes, longer service life

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 the CERATIZIT Group.

1. Boring bar

Big end roughing, semi-finishing and chamfering

  • Tool combines three machining steps, reducing tool changes and thus the overall machining time
  • Extremely stable tangential inserts arranged vertically and horizontally for rough machining (forging skin) with 8 usable cutting edges
  • Defined constant allowance for finishing due to adjustable short clamping holder with sturdy S-insert with 4 usable cutting edges
  • Sturdy S-inserts with 4 usable cutting edges for chamfering both sides
  • Extremely cost-effective tool concept thanks to the high quantity of usable cutting edges
  • Also available with CERAsmart detector

2. Snap-on tool for tilt drill head

Big end finish machining

  • Sturdy S-insert with 4 cutting edges
  • Outstanding drilling quality with no retraction scoring
  • Long service life and high efficiency

3. Reamax Fix

Reaming including chamfering (before pressing-in the brass bushing)

  • Six-edged reaming head with chamfer insert for a short machining time of significantly under 1 second
  • Chip breaker geometry of the reaming edges for very short, small chips resulting in the highest levels of process security
  • Finish for a defined surface roughness
  • Highly efficient due to cost-effective solid carbide high-speed reamer and 4-edged S-insert without logistics expenditure for regrinding
  • No adjustment required (plug & play)

         

6. Turbocharger machining
No-compromise tools for turbo speed

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
  • Thro' 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
To product

3. MaxiMill A273 face milling cutter

Uncompromising milling of the manifold face

  • 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 40 – 250 mm as standard
To product
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