Press releases - Mahle.com

mahle.com

Press releases - Mahle.com

P R E S S R E L E A S E

Assembled camshaft for commercial

vehicles goes into series production

Hanover, September 2012 – The valve train in a combustion

engine is continuously subjected to high mechanical loads.

Advances in reducing friction and weight have therefore had a

direct influence on the efficiency of the entire engine, and thus

reduced fuel consumption and CO2 emissions. MAHLE's

assembled camshaft achieves a weight advantage of around 30

percent in its first series application.

Cast iron camshafts have long been used for light commercial

vehicles, while medium to heavy commercial vehicles have

resorted to forged steel camshafts. These technologies require

relatively high tooling costs, which are very disadvantageous

relative to passenger cars due to the low production quantities.

Assembled camshafts allow higher contact pressure between

the cam lobe and cam follower in comparison to cast camshafts,

and offer significant weight advantages over steel camshafts

made from solid material or raw forgings. The great design

flexibility of the individual assembled components also provides

cost advantages with respect to materials and design. For

example, very durable cam lobes are made of roller bearing

steel and then inductively hardened, while the drive input and

output elements can be made of less expensive materials, as

needed.

The MAHLE production method for assembled camshafts

provides optimal conditions for flexible manufacturing. Using a

thermal shrink-fit method, parts such as cam lobes, pulsegenerator

wheels, and driving and output elements are joined to

precision steel tubes having a high degree of torsional stiffness

and flexural strength. The purely elastic shrink-fit composite

guarantees a consistently high interference fit of the joined

components over the entire service life of two million kilometers

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equired for commercial vehicle engines. Assembled camshafts

that are not produced with the MAHLE manufacturing process,

but by means of plastic deformation at the joint seating

surfaces, demonstrate an aging effect; the joint becomes

weaker over the service life. MAHLE has produced assembled

commercial vehicle camshafts under near-series conditions and

performed successful endurance tests. With the series launch

that is currently underway at a well-known manufacturer in

Europe, the first assembled camshafts for commercial vehicles

from MAHLE will see large numbers built in series production. In

this series design, the camshaft achieves weight savings of

about 30 percent.

In the course of rising requirements for modern engines,

additional potential gains are being evaluated for assembled

camshafts, and the component is under ongoing development.

One possibility is to use a rolling bearing in place of the

hydrodynamic plain bearing that is typical for camshafts. The

resulting reduction in frictional loss and optimized oil balance

further contributes to optimizing CO2 and reducing fuel consumption

in the powertrain. MAHLE is currently investigating the

potential of this technology for use in commercial vehicles.

Assembled camshafts for commercial vehicles from MAHLE

enable modern commercial vehicle engines to fulfill increasing

requirements related to service life at a low cost, while simultaneously

reducing weight and optimizing fuel consumption. A

clear trend toward the use of assembled camshafts can be seen

in the development of future commercial vehicle engines.

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About MAHLE

The MAHLE Group is one of the 30 largest companies in the

automotive supply industry worldwide. With its two business units

Engine Systems and Components and Filtration and Engine

Peripherals, MAHLE ranks among the top three systems suppliers

worldwide for piston systems, cylinder components, as well as

valve train, air management, and liquid management systems.

MAHLE’s industrial activities are combined in the Industry

business unit. These include the areas of large engines, industrial

filtration, as well as cooling and air conditioning systems. The

Aftermarket business unit serves the independent spare parts

market with MAHLE products in OE quality. In 2011, the MAHLE

Group generated sales of approximately EUR 6 billion; around

49,000 employees work at over 100 production plants and eight

research and development centers.

Further queries:

MAHLE GmbH

Ruben Danisch

Corporate Communications/Public Relations

Pragstrasse 26–46

70376 Stuttgart

Germany

Phone: +49 (0) 711/501-12199

Fax: +49 (0) 711/501-13700

ruben.danisch@mahle.com

Press releases and image service can also be downloaded from:

www.mahle.com/news & press

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