Crank Shaft Manufacturing

8/11/2019 Crank Shaft Manufacturing

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Crankshaft machining

EN


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CERATIZIT - secrets of success

The views and focus of our businesspartners matter

Innovative and flexiblethinking matters

Communication matters

Employee developmentmatters

Our environmentmatters

Secrets of success

Corporate values

Tailored cutting tool solutions

Professionalism matters

CERATIZIT is your partner for exceptional hardmaterial solutions. Hard materials and toolsfrom CERATIZIT - our solutions to complexproblems are an integral part of our customerssuccess. Our products guarantee: economy -long life - speed! And it is precisely thiscombination which gives our business partnersa direct competitive advantage.

Premier performance is only possible througha total appreciation of the requirements of ourbusiness partners. A performance achievedthrough flexible thinking and continuousdialogue with our customers. A pioneering

spirit and a deep understanding of powdermetallurgy characterize the history ofCERATIZIT. One of the attributes of ourcompany philosophy is the search forperfection: target oriented - sustainably -passionately!

Intensive research and development activities,taking into account the precise requirementsand working processes of the customer,are todays investment for the solutions oftomorrow - and beyond.

Cutting materials, coatings, inserts, toolingsystems and machining solutions - all this isincluded in the cutting tool division atCERATIZIT.

Worldwide well-known companies processadvanced materials applying cutting toolproducts from CERATIZIT: from the automotive

industry to the aerospace industry, mechanicalengineering, and tool construction to the oilindustry.

The basis of these long-term business relationsis the faith of the customers in the extensiveknow-how of the carbide specialists.


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Crankshaft machining

External milling, internal milling, turning, turn-turn-broaching, broaching.HyperCoat carbides and an optimized cutting edge system make the difference.CERATIZIT carbides and tooling solutions have been applied in batch production bywell-known crankshaft manufacturers for many years.

Car crankshafts

Truck crankshafts

Large crankshafts for generators and marine engines

Materials:

Alloyed steel

Spheroidal cast iron

Modern cast iron types such as CGI and ADI

No. 1 in powder metallurgy

High level of vertical integration from the raw material to the finished insert

Over 30 years of experience in crankshaft machining

Everything from one source

Durable tools

Reliable cutting materials

Simple tool handling

Distinguishing features

The views and focus of our business partners matter

Instead of talking product with customers, we work on real solutions for business partners.


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www.e-techstore.comwww.ceratizit.com

Specific team for OEM services to guarantee professional project processing

Close cooperation with machine manufacturers

Complete machining concepts and tooling solutions: workflow, tools, cutting

parameters, necessary tools, process times, process costs

Tooling Academy in Reutte supports process optimization

Support for acceptance and commissioning runs

Detailed project documentation

Worldwide distribution and service network

CERATIZIT not only offers you excellent cutting tools but also customized completesolutions for optimal machining of your work pieces on new projects.

CERATIZIT service

Up-to-the-minute CERATIZIT product catalogue including all technical details

Live-availability check for more than 20,000 standard articles

Easy and quick processing

More than 100,000 possibilities of toolcombinations online

Access 24 hours a day

Shipment tracking via Internet(Track & Trace)


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Tools for crankshaft machining

Maximum performance capacity of the cutting materials combined with thehigh-quality CERATIZIT tools ensures economic production.

CERATIZIT is your partner in crankshaft machining as a full-range supplier.

End-hole and counter-bore (2)

applying MaxiDrill, High Feed Drill and

EcoCut tools

Spigot and journal

machining (3)


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Machining of thrust faces (7)

Milling ends (1)with MaxiMill tools

External milling (4) Internal milling (5) Turn-turn-broaching (6)


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Machining steps

16 cutting edges

Double-sided insert with positive rake and clearance reduced cutting forces

Close pitch maximum economy, reducedcycle time

HyperCoat grades for cast iron and steel

Very good surface quality

MaxiMill A273

Centre drills

Step drills

Carbide drills

High-performance insert drill

4 usable cutting edges

MaxiDrill HFD

Suitable for universal application

Optimum force compensation for drilling without deviation

MaxiDrill Classic

Drilling and turning with only one tool Diameter 4 mm and greater

EcoCut

2) End-hole and counter-bore

1) Milling ends

see also brochures No. 505,

MaxiMill 181 and No. 181, EcoCut

see also brochure No. 467,

MaxiMill 273


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Machining steps

Customized tooling systems

MaxiLock D insert clamping

ISO turning inserts

MSS parting and grooving program

Adapters HSK-T CAPTO Standard adapters

Turning tools

Optimized cycle time

Easy handling

Ideal for rough machining

Overturning tool

3) Spigot, flange and end-journal machining

see also brochures No. 148,

MaxiMill 512 and No. 512, HSK-T


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Machining steps

High metal removal rate

High process security

Maximum stability Suitable for difficult conditions

Flexible thanks to cassettes

Upon request pre-set with shims

Setting mechanism available

Application: machining of main and pin bearings

Advantages

5) Internal milling

4) External milling

Long intervals between tool changes

High cutting speed

External machining of webs

Flexible thanks to cassettes

Upon request pre-set with shims

Setting mechanism available

Application: machining of main and pin bearings

Advantages


11/2011

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Milling innovations

NEWS:

Axial run-out within 0.005 mm

For maximum surface quality andgeometric accuracy

Adjustable tools

High precision without setting

Radial and axial run-out within 0.025 mm

Shims

Insert clamping with precise repeatability for cutting edges

Insert seat design clearance

Stable

User-friendly

Precise repeatability

Cassette clamping system X-Lock

Cutting speed 4501000 m/min

Cycle time reduced by 50%

High-speed milling with ceramic inserts

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12/2012

Machining steps

Standard ISO inserts

MaxiLock D insert clamping

Inserts for broaching

Cassettes

Inserts for broaching

Minimized downtime = short chip to chip time

6) Turn-turn-broaching, broaching

7) Machining of thrust faces

CERMET

Carbide

CBN

Masterfinish inserts

Adjustable tooling systems

Everything from one source

Application: machining of main bearings

Advantages


13/2013

Special tools according to customers specifications

These tools have greatly improved productivity:

Talk to our technical experts. We will help you optimize the

machining of your component.


14/2014

Success stories

Criteria:> Machining of 80% cast iron and 20% steel

crankshafts> Swarf control for steel crankshafts> Tool life when cast iron machining> Tolerance of undercut radius

Result:> Optimized swarf control

> Tool life increased by 50%> Undercut radius within tolerance

(criterion for release)

Technical data:Work piece: crankshaft machiningMaterial: GGG-60 (80%) / steel (20%)Hardness: 250 HB (cast iron) / machined surfaceMachine: BoehringerTool: turn-turn-broach discInsert: Z 10005007-0Grade: 1002 (hard metal, CVD coated)

Cutting data:> CERATIZIT vc = 180 m/min ap= 2 mm f = 0.31 mm dry

> Competitor vc = 180 m/min ap= 2 mm f = 0.31 mm

dry

Criteria:> Tool life> Surface finish> Dimensional accuracy

Result:> Tool life increased by 18%> Cost per part reduced by 25%> Component quality guaranteed

Technical data:Work piece: 5-cylinder crankshaftMaterial: GGG-60Tensile strength: 650 N/m2

Machine: BoehringerTool: side and face milling cutter 700 mmInsert: Z10007823-0Grade: 1066 (hard metal, PVD coated)

Cutting data:> CERATIZIT vc = 200 m/min ap= 3.5 mm hmax = 0.23 mm

dry

> Competitor vc = 200 m/min ap= 3.5 mm hmax = 0.23 mm

dry


15/2015

Success stories

Criteria:> Surface finish> Swarf control> Dimensional accuracy

> Cycle time

Result:> No interruption of production caused by

lack of swarf control> Tool life increased by 50%> No surface damage caused by

lack of swarf control> Process security guaranteed

Technical data:Work piece: crankshaft (end machining)Material: 38 CrMnMoS 6Tensile strength: 1100 1200 N/m2

Machine: Edschede transfer lineTool: special toolInsert: TNMG 160408EN-TMFGrade: CTC1115

Cutting data:> CERATIZIT vc = 84 m/min ap= 1 2 mm fz = 0.8 mm

dry

> Competitor vc = 84 m/min ap= 1 2 mm fz = 0.18 mm

dry

Criteria:> Cycle time> Surfac finish> Cutting force

Result:> Cassette types reduced from 6 to 2

reduced stock keeping

> Number of cutting edges increased by 50%> Feed rate increased by 50%> Increased number of usable cutting edges per

insert

Technical data:Work piece: large crankshaftMaterial: 34CrNiMo6Tensile strength: > 950 N/m2

Machine: Niles N42 CTool: side and face milling cutter 660 mm

Insert: special insertGrade: 1112 (hard metal, PVD coated)

Cutting data:> CERATIZIT vc = 176 m/min ap = 8 mm f = 0.29 mm

dry

> Competitor vc = 176 m/min ap = 8 mm f = 0.29mm

dry


16/2016

Machining sketch


17/2017


18/2018


19/2019

www.ceratizit.com

CERATIZIT worldwide

Production sites in the three big economicareas with a worldwide network of CERATIZITsales and support engineers plus manyCERATIZIT distribution partners guaranteecustomer vicinity.

We maintain the dialogue with our customersand strive for long-term partnerships.

CERATIZIT worldwide production sites and support centres

CERATIZIT worldwide sales centres

CERATIZIT worldwide distribution partner network

Parent company in

Luxembourg

CERATIZIT Luxembourg Srl

Route de Holzem 101

L-8232 Mamer

Tel.: +352 312 085-1

Fax: +352 311 911

E-mail: [email protected]

www.ceratizit.com

CERATIZIT worldwide

CERATIZIT worldwide

Find your personal distribution partner at:

Contact for further information:

CERATIZIT Austria Gesellschaft m.b.H.

A-6600 Reutte/Tyrol

Tel.: +43 (5672) 200-0

Fax: +43 (5672) 200-502

E-mail: [email protected]

www.ceratizit.com


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