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
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. SEMI | FINISH valve ring and valve guide
2. Face milling with the suction effect
3. Counterboring the core plug hole
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. High-precision finish machining of the cylinder bore
2. Milling the microcontour for wire arc spraying (LDS) pre-machining
3. Uncompromising roughing with high cutting depths and casting burr
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
2. Pin and main bearing milling
3. Deep hole drilling of oil passage bores
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. Over turning and countersinking the fuel line connection
2. External thread milling on the pressure pipe connections
3. Thread milling the connection thread
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. Big end finish machining
2. High-precision finishing for the big and small end
3. Solid drilling, counterboring of the big and small end including chamfering in a single operation
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. Finishing the V-belt with interpolation recess turning
2. Complete finishing of the V-belt side
3. Uncompromising milling of the manifold face