ENGINEERED PRODUCTIVITY SOLUTIONS

25% faster than with conventional machining

Turbocharger machining

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Benefits for you: Significantreductioninmachiningprocessby25% Increaseinultra-precisemachining Toollifeincreasedbyseveraldegrees Fewertoolsrequired Integratedassistanceandmonitoringsystem Ahighdegreeofautomationdesigned

forseriesproduction Increaseinlong-termqualityofturbochargers

Requirements for turbocharger manufacturing:

Relating to the material Extremelyhighrequirementsrelatingtothermomechanicalproperties,highheatresistance–useintemperaturesofupto1100°Cforpetrolengines

Useofhigh-alloy,high-temperature-resistantmaterialswithahighnickelandchromecontent

Extremelylowthermalconductivity(Heatisdirectedintothemachiningtool)

Strongtendencytowardsstrainhardening Highlyabrasivecastskin,edgezonehardness

upto450HV0.5 Austeniticmatrixwithchromiumcarbidesrequireshighcuttingforces,whichresultinarelativelyshorttoollife

Inshort,abrasiveanddifficulttocut

Relating to machining Highrequirementsrelatingtoformandpositiontolerances Automatedseriesproduction Reductionofcostsperpieceandthemachiningtime

Productivity PLUS! A highly efficient solution in turbocharger manufacturing from STAMA Maschinenfabrik GmbH and KOMET GROUP GmbH

ASUCCESSFULCOLLABORATIONTHETURNKEYSOLUTIONFORMACHININGNEWGENERATIONSOFTURBOCHARGERS

A time saving of up to 67%. Machining time reduced by up to 25%.

ThecombinationoftheSTAMAMT838TWINmilling-turningcentreandKOMET®machiningoptimisationwithaspecialKomTronic®U-axistoolissettingnewstandards.Atimesav-ing of up to 67% is achieved for V-belt machining alone.This is mainly the result of interpolation grooving andturning, which replaces the circular milling processwhich was originally used, and the result of the use ofKOMET®U-axissystems.The result: The time required for the entire machin-ing process for the component is reduced by 25%.Inadditiontodrasticallyreducedtoolcosts.

Turbochargerhousing

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Machining strategy

Rotationallysymmetricalmachiningwithhighly asymmetric component

UseoffreelyprogrammableKOMETKomTronic®U-axissystemsenables any type of contour machining and turningonpartswhicharenotrotationallysymmetrical.Throughthecombineduseofcustomised snap-on toolsandoptimallyselected indexable inserts

Machiningcontoursinboresaswellasinternalandexternalmachiningresultsina significant reduction

in production times, better surface quality, and improved dimensional accuracy

Fewertoolsrequired Useof3D-printed special toolswithinnovativecoolantchannelsadaptedtotheprocess

The solution on the machine side

Double-spindleSTAMAmilling-turningcentre MT838TWINwithHSK-A100 Highlydynamicandstablecompletemachining

withmillingandturning Completefreedominthechoiceandsequenceofoptions

Productivity PLUS! KOMET® tool solutions

Examples of ultra-precise machining

INNOVATIVESOLUTIONSFORTURBOCHARGERMANUFACTURING

Pre-machining of V-belt outer diameter – KOMET® interpolation grooving and turning tool

Benefits for you:

Extremelystabletooldesign

Specialadaptationofthecuttingedgegeometry

tothemachiningprocesswithregardto

machiningtimeandstability

Internalcoolantsupply

directlytothetool's

cuttingedge

Finish machining of counter bearing conical hole – KOMET KomTronic® U-axis systems Withsteppedsnap-ontoolwithfourindexableinserts.

Benefits for you:

Completefinishmachiningwithasingletool

Enablesmaximumprecisiontobeachieved

99%useofstandardindexableinserts

Directcoolantsupplytotheindividualcuttingedges

Integratedpositionmeasuringsystem

Short,stabletooldesignthanks

tooptimalcompactconnection

Finish machining of V-belt outer diameter – KOMET KomTronic® U-axis systems With 3D-printed snap-on tool and indexable inserts in

special designs, with three cutting edges with ground

recessgeometryandflute.

Benefits for you:

Considerablyhighercuttingvalues

thanwithconventionalmachining

Integratedpositionmeasuringsystem

Short,stabletooldesignthanks

tooptimalcompactconnection

KOMET® arbor face-milling cutter for machining of turbo chargers Ø 50 – 125 mmWithdouble-sidedoctagonalindexableinsertswith

16usablecuttingedges.

Benefits for you:

Robustdesign,stableandsecurepositioninthebasicbody

Specialcuttingmaterialsuitableforthetoughest

thermomechanicalrequirements

Defined,stablecuttingedgeguidance

Maximumproductivity,processrelia-

bilityandcost-efficiencyguaranteed

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Selected machining examples – Conventional machining vs. KOMET® strategy

OPTIMISATIONOFTHEMACHININGPROCESS

Now KOMET KomTronic® U-axis systems with direct position measuring system and 3D-printed snap-on tool

Advantages

Significantlyhighercuttingspeedscanbeachieved Considerablereductioninmachiningtimes Rapidamortisation

Now Complete manufacturing with KOMET® interpolation grooving and turning tool

Advantages

Timereductionofupto47% Circularmilling75sec–reductiontobelow40sec

withinterpolationgroovingandturning Highlevelofprocessreliability Reducesnumberoftoolsrequiredbyone,

eliminatingtheneedforchangeovertime

Previously Conventional finish machining with interpolation grooving and turning tool

Machiningprocessisheavilydependentonthemachineperformance(cuttingspeed,feedrate,etc.)

Previously Conventional roughing with two tools

Firststep: Pre-machiningwithspecialboringbarSecondstep: Pre-machiningwithspecialcircular millingcutter100

Process: Finish machining of V-belt outer diameter

Process: Pre-machining of V-belt outer diameter

FinishmachiningofV-belt FinishmachiningofV-belt

Pre-machiningofV-beltPre-machiningofV-beltsemi,circular

Pre-machiningofV-beltouterdiameter

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Now KOMET KomTronic® U-axis systems with direct position measuring system and 3D-printed snap-on tool

Advantages

Significantlyhighercuttingspeedscanbeachieved Considerablereductioninmachiningtimes Rapidamortisation

Now KOMET KomTronic® U-axis systems with stepped snap-on tool and direct

position measuring system

Advantages

Completefinishmachining Increasedpositioningaccuracyandprocessreliability FreelyprogrammableU-axisenablesuseofstandardcuttingedgesforcomplicatedcontours.

Effect:Lowercuttingpressureandmachining ofthecontourlineinasingleoperation

Result:Lowermachiningforces,longertoollife andextremelylongshaperetentionasaresult

Previously Conventional counter bearing machining with up to four tools

Firststep: SemifinishlinerSecondstep:SemifinishbearingringThirdstep: SemifinishcounterbearingFourthstep:Semifinishliner

Process: Finish machining of counter bearing conical hole

FinishmachiningofV-beltwithKomTronic®U-axistoolHSK-A100Monospecialboringbar(adjustable)HSK-100Monospecialboringbar

HSK-A100Monospecialboringbar HSK-A100Monospecialboringbar

Watch now! www.kometgroup.com/turbocharger

YoucanalsofindallKOMET®videosonourYouTubechannel:www.youtube.com/kometgroup

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TURBOCHARGERMANUFACTURING

Independent study by Reutlingen University, Prof. Dr.-Ing. Helmut Nebeling verifies the cost-effectiveness of the innovative turbocharger manufacturing process

Costs per part

Example: Reduction in time required for "V-belt" finishing

Cutting values achieved for "Trumpet"

U-axis enables efficient, quicker and more cost-effective machining of turbocharger housings

Interpolationmilling 174sec

U-axis 30sec

Vc 140m/min

f 0.12mm/rev

ap 0.3

Formtolerance <0.020mm

Rz <16m

Costsineuros

U-axisConventional

Labourcosts Toolcosts Machinerycosts

Conventional:Roughingandfinishing inthemillingprocess U-axis:RoughingandfinishingwithU-axis

Conventional U-axis

Machinerycosts 12.53 12.18

Toolcosts 19.87 0.40

Labourcosts 10.05 6.03

Totalcosts 51.44 18.61

21.53

12.18

6.03

19.87

10.05

0.40

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Materialdatabaseandcuttingvaluesdatabase withempiricalvalues Evaluation of:Calculationofservicelifeanalysis

fortools,CPP(costperpart)saving,amortisation, toolcomparisonsandplanning

ToolScopes record and document the machine's in-ternal data during the machining process, such asthe torque of a spindle or name of the current pro-gramme. ToolScope apps can use this data to mon-itor the process in real time or optimise the feed overrideduringtheprocess.ToolScopecanbeusedtodocumentmon-itoringresultsandautomaticallytransferthisdocumentationtothecustomerserverforarchiving.KOMET®offersaddi-tionalsoftwareforoptimisingdatastorage.

KOMET®BRINKHAUSTOOLSCOPEASSISTANCESYSTEMINUSEFORTURBOCHARGERMACHINING

Benefits for you: Reducedcycletimeforfacemilling Fingerprintingofprocessespriortothestart

ofseriesproduction Automatedaverageprocessmonitoring Reducedtoolcoststhankstowear-dependent

toolchange Automatedmonitoringofthemachinestatus Documentationofin-processmeasuredvalueswithautomatedconnectiontocustomerITsystems

Moreinformationcanbefoundatwww.thomann.com/en

Machiningprocessesforturbochargersplacenewdemandson processes and machines in terms of quality assurance.WiththeToolScopeassistancesystem,KOMET®fullysatis-fiesthesedemandsaswell.WithToolScope, theKOMETGROUP is theonly toolmanu-facturer tooffer a true Industry4.0 solution, even for smallandmedium-sizedcompanies.Turbochargermachiningproces-sesenablethefullpotentialofthissystemtocomeintoplay.

Intheearlyplanningstageforturbochargermachining,thebasisforthemachiningtimesandcostanalysisisformedus-ingtheCutView®planningtool.TheKOMETGROUPtoolequipment in conjunction with the STAMA MT 838 TWINmilling-turningcentreprovides thebasis for thismachiningexample.

With regard to this project, CutView® is characterised by the following features:

Quickandeasyoperationofmachiningprocesses, toolsandmachines Easeofuseandsmoothdataexchangebased

onMicrosoftExcel Determineshowlongaworkpiecerunsonamachine Timecalculationforadjustingthemachiningsequence Toolcalculationwithcostsinvolved Calculationoftorque,cuttingperformance,

feedpowerandprimaryprocessingtime

COSTBREAKDOWNUSINGCUTVIEW®PLANNINGSOFTWARE

1. Monitoringprocessesareclearlydisplayed.2. Cleardisplays(piececounterhere)facilitatetheunderstanding ofprocessesinthemachine.3. ToolScopedatacanbequicklyvisualised.KOMET®evenoffers Exceltemplatestohelpyoureachyourgoalfaster.

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www.kometgroup.com

39901 81200-08/17 · © 2017 KOMET GROUP GmbH · We reserve the right to make modifications.

8. What workpiece diameters can be machined?Therangeofapplicationis0.5–500mm,takingintoconsid-erationtherelevantprojectionlengthandattachmentpoint.

9. What is the maximum possible number of different diameters or cutting edges?Anynumberofcuttingedgesarepossible.Thisisdependentonthetoollengthandtoolwidth(slide)of40or60mmre-spectively,andthecontrolsystem.

10. How is the tool system set?TheU-axisisalwayschangedinthecentralposition.Thisenablesthesnap-ontooltobemeasuredonadummyinthepresettingdevice.Inaddition,post-processmeasurementwithautomatedcuttingedgecorrectionispossibleviathetoolmanagement.

11. What are the maintenance and service intervals? Recommendedonceayear,oreverytwoyearsdependingonuse

12. How long is the expected service life? Withregularmaintenanceandcareandthereplacementofwearparts,aservicelifeof>6500operatinghoursisrealistic,correspondingtoapproximately10years.

13. How accurate is the system for double-spindle ma-chining?Bothsystemsshouldbeusedoffset(180°)dependingontheimbalance.Aswithasingle-spindlemachine,withthedouble-spindlemachinetheaccuraciesinpoint1areachievedwithexacttoolpresettingoraZ-axisthatcanbeadjusted/correctedseparately.

14. What is the maximum size that can be machined with HSK63 or HSK100? KomTronic®UAS-115:Uptodia.approx.250mmKomTronic®UAS-160:Uptodia.approx.500mmtakingintoconsiderationtherelevantprojectionlengthandattachmentpoint.

15. Are the U-axes more suitable for vertical machining than horizontal machining? U-axesareusedbothverticallyandhorizontally.Theadvantagesanddisadvantageshereshouldbeconsideredtobethesameasforamechanicaltool(centrifugalforces).

1. What levels of accuracy can be achieved with the KomTronic® U-axis? Diameter of 0.02 mm with no measuring system onthe slide, diameter of 0.005 mm with a measuringsystem. The measuring system can perform analysiswith a measuring accuracy of 0.0001 mm (accuracy isdependent on other machining factors, such as toolchangeerrors,wearonthecuttingedge,etc.)

2. How can the position of the inserts be corrected?Onthetoolviashortclampholdersorforeachcuttingedgedirectlyviathetoolmanagement.

3. Does the U-axis always need to be re-measured each time the inserts are changed?No, theU-axis or slide is always in the sameposition. Theinsertpositioncanbecorrecteddirectlyinthemachineviaanin-processmeasurement.

4. Does the KomTronic® U-axis need to be removed from the machine in order to measure the tool?No,thisisconvenientlycarriedoutbyintegratinganattachmentpointconnection(optional).

5. What is the maximum speed limit?Withthesingleslidebalancedinthecentralposition,themax-imumspeedis4000rpm,adjusteddependingonthestroke.At up to 8000 rpm over the entire axis stroke (see the"KomTronic®drawbartoolsformachiningcentres"brochure)

6. Can the KomTronic® U-axis also be used for roughing?Avarietyofmachiningprocessescanbeused(finishingandroughing).Theslidehasamaximumpowerof4000Nandapermissibletorqueof200Nm.However,thepossibleusagedatadependsontheoveralllengthofthetoolandtheU-axis.

7. How is the U-axis driven?The U-axis is driven via a servo motor. The slides for theUAS115/160 seriesaredrivenviaa roller threaddrivewithnoplay.

FAQ–questionsandanswersregardingKOMET®U-axistools