Heavy duty machining
Crank shaft machining
Crankshaft machining The right milling tool for every processing step
The right tool for every processing step Boehlerit has long-standing expertise and a full range of tools for crankshaft and camshaft machining at its disposal. The tools are designed on a case-bycase basis, in accordance with individual customer requirements. Our tailor-made solutions range from conception all the way to the commissioning of tooling systems using specially developed cutting materials and geometries. We are proud to share our many years‘ experience and our know-how.
Full-service provider
- Initial fitting
- Commissioning
- Continuous process
- optimisation regarding cycle times, quantities and workpiece tolerances
- Supply of spare parts
- Tool repair
- Service and application engineers worldwide
- Training events
Milling of pin bearings and main bearings of crankshafts
External milling cutter for large-volume production of small and medium-size crankshafts.External milling cutter with a diameter of up to 2,100 mm for the largest
monobloc shafts (marine crankshafts and stationary drives).
- Shortest cycle times
- High cutting speeds
Internal milling cutter for the machining of medium-size crankshafts (trucks) and even of ship‘s engines.
- Stable machining conditions
- Highest number of teeth
- Highest machining performance
Turn-milling tools for large crankshafts
Helical cutter
- Milling of cheeks to the fi nal dimensions in a single cutting process
- Lengths of up to 500 mm
- Positive cutting geometries
- Cutting edge arrangement is adapted to turn-milling conditions
Form cutter
- Milling of chamfers to the fi nal dimensions in a single cutting process
- Positive cutting geometries
- Soft cut thanks to offset inserts
Tools for the turn-milling of flange and stub ends
Turn-milling with stationary clamped workpieces with workpiece-specifi c, bell-shaped special tools
Turn-milling with rotating workpieces
Turn-tools and turn-broaching tools
Modular tools with a cartridge structure for turn and turn-broaching operations on the main bearings of crankshafts for passenger car engines.
- Exchangeable cartridges
- Tangential inserts for heavy cutting
- ISO inserts to keep costs low
Bar peeling
Bar peeling – a heavy-duty machining process
Bar peeling refers to a kinematically reversed longitudinal cylindrical turning process and is one of the most sophisticated machining processes around. The workpiece is concentrically fed through a rotating shaving head and the process know-how is mostly concentrated directly at the working area. Boehlerit provides complete tooling systems for successful rotary shaving, consisting of a bar peeling head, holder and cartridge.
Essentially, bar peeling constitutes a heavy-duty machining process that is usually applied to diameters ranging from 5 to 600 millimetres. With standard materials, feed rates of up to 18 millimetres per turn are achieved today, a rate that is many times higher than that achieved with general turning. Using appropriate cartridge systems, cutting depths of up to 15 millimetres are realised. Turnaround times of 600 to 800 bars with an 80-millimetre diameter made of standard materials also bear witness to the performance capacity of the used indexable inserts. But bar peeling is also a heavy-duty process in terms of difficulty. The processes take place using enormous amounts of cooling lubricants, which means that they are not visible to the machine operator. At the same time, tools and machines are put under an enormous amount of pressure. In the long run, this may lead to vibration or stability problems.
Another aggravating factor is that cold finishing often utilises materials that are difficult to machine, such as stainless steels or nickel-base alloys, and that forged bars in particular are often quite warped and unsymmetrical. To a large extent, process reliability is down to the experience of the machine operator and his sense of hearing. The breaking of indexable inserts in particular must be prevented, as this would cause enormous damage to the cartridges and possibly also the shaving head and the guide rollers in the insert apparatus.
Optimum processing is really only possible by assessing the process results, the dimensional accuracy and the achieved surface quality. Experienced operators will also know how to assess the chipping and the wear and tear of the indexable insert. The adaptation of process parameters and the fine-tuning of the inserts are usually performed in close cooperation with the insert manufacturer and through the composition of the cutting material and geometries, i.e. length of the cutting edge, chip-breaking geometries and design of the supporting chamfers.
Shaving
The economic method to produce peeled steel and non ferrous metals from coil to coil for diameters from about 3 to 15 mm.
Shaving dies designed to the requriements of material and machine on request.
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