stories on hard material matters - Ceratizit S.A.

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20 CRANKSHAFT MACHINING AT AUDI HUNGARIA Interview with László Janó, product segment V6, mechanical production department at Audi Hungaria Mr Janó, how long does the machining of a crankshaft take? Janó: “There are several ways of looking at this. You could say that at the end of the production line a finished crankshaft comes out every 49 seconds. This is the cycle time of the line. Including the buffers (per line there are 5,700 cranks in the buffers) the flow time for 1,400 parts per day amounts to around six days.” How important is the role of the tools in this production line? Janó: “Extremely important. This line is very complex and flexible. The investment for such a line, for instance, is three times as high as for a line for the production of cylinder heads. For such a complex machining method process security has to be very good. In the automated machining chain tool life has to be consistently high. 65% of the costs are tooling costs. The tools also play a very important role.“ What is the proportion of non conforming material? Janó: “The tolerances for a crankshaft are very close. The entire line is designed for this and is continuously opti- mized. Quality control is also very intensive. For the 3.0 TDI engine a 100% rupture test is carried out. For me the quality of the final product is important, not so much the share of non conforming material. In the last four years Patrick Zobl, product manager at CERATIZIT, describes crankshaft machining in detail Technique for crankshaft machining • High cutting speeds (up to 260 m/min) • Planetary milling cutters with diameters ranging from 350mm to 750mm • Dry machining leading to high temperature stress on the cutting material • High number of teeth of the planetary milling cutters (40 up to 200 teeth) • Main bearing and webs are machined at the same time with two planetary milling cutters • Due to the length and the relatively small diameter of the crankshaft machining stability is low imp:act 01/08 László Janó, product segment V6 with a finished Audi crankshaft. only two crankshafts have been returned to us; this was due to faulty material, not to faulty machining.“ What can a crankshaft withstand? Janó: “I don‘t want to give numbers, but the basic rule is that the crankshaft has to withstand three times as much as the engine.“ Requirements with regard to the CERATIZIT inserts • High resistance to thermal shock • Consistent quality of the cutting material providing process security at the customer • Long tool life, therefore low tool changing costs • Smooth surface thanks to lower frictional heat and wear Materials used in crankshafts • Cast iron materials for engines when subject to reduced stress in the engine • Alloyed steel (Cr, Ni, Mo) with high fatigue strength in engines which are subject to higher stress or to reduce weight
CRANKSHAFT MACHINING AT AUDI HUNGARIA AUDI HUNGARIA MOTOR in Györ, Hungary: in 2006 alone more than 23,500 vehicles and close to two million engines left the plant. Basic characteristics of CERATIZIT inserts • Geometry of the insert is mainly defined by the profile of the crankshaft • CERATIZIT chooses the insert to be applied as well as the geometry of the cutting edge Steps in the production of a crankshaft a. Preparation 1. Cutting and centring 2. Internal and external profile milling of the pin of the bearing and connection rod bearing pin 3. Turning of the main bearing pins and the end parts 4. Deburring 5. Solid carbide deep hole drilling b. Hardening (induction hardening) c. Finishing 1. Hard turning 2. Threading 3. Chain wheel broaching 4. CBN grinding 5. Fluorescent rupture test 6. Dynamic balancing 7. Finishing (polishing and lapping) d. Quality test 21
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Page 3 and 4: Today, CERATIZIT is already the wor
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Page 11 and 12: Interview with Magnus Dåverhög, p
Page 13 and 14: Due to the saline air and the stron
Page 15 and 16: World innovation: machining of alum
Page 17 and 18: Interview with Sanjay Sabherwal, Ma
Page 19: Three highly modern complete automa
Page 23 and 24: Interview with the leading manageme
Page 25 and 26: is extremely hard on the tip but ra
Page 27 and 28: Change in leadership at CERATIZIT G
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Page 35 and 36: Cutting tools for medical systems:
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Page 39 and 40: In one word: flexibility “The aut
Page 41 and 42: Interview with Enzo Casanova Head o
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