22.07.2025
Tool solutions for modern combustion engines
MAPAL optimises machining for crankshafts and valve seats
Production figures for vehicles with combustion engines are in decline but are still very high, at around 75 million cars built per year. Ample reason for the industry to continue seeking ways to optimise series production. MAPAL is lending its support with new tool solutions for modern combustion and hybrid engines.
One-shot solution for drilling and deburring
This also determines the length of the drill. To process the entire crankshaft in one go, tools with lengths between 600 and 800 mm are required. MAPAL achieves this with a modular system. The drill body is a special replaceable head holder with TTS (Torque Transfer System) connection that guarantees an extremely stable joint. The MAPAL connection features optimal torque transmission and high changeover and radial run-out accuracies. For the desired tool length, the tool holder is screwed onto an extension. The TTD replaceable drill head at the tip is available in various geometric designs depending on machine performance.
One challenge in machining is the burrs that occur in the metal when the drill goes in and out. These burrs were previously removed in a separate machining step. MAPAL now offers a one-shot solution for simultaneous drilling and deburring. This is made possible by a modular combination tool in which an additional chamfer insert is integrated into the chamfer behind the drill head. This SNAP18 module is a miniaturised deburring system that has been individually designed by HEULE Precision Tools for the application. For reliable forward and reverse deburring, a small spring controls the insert and ensures the pre-drilled diameter is chamfered to the nearest tenth and is not damaged during deburring.
Twelve inserts for valve seats
Further increase in efficiency possible for larger valve seat rings
Eine Verdoppelung der Anzahl vom Schneidkanten wirkt sich für die Anwender direkt auf die Produktionskosten aus: Die Cost per Part halbieren sich dadurch. Hinzu kommt ein Standzeitgewinn durch den Einsatz von PcBN-Hochleistungsschneidstoffen, die innerhalb der MAPAL Gruppe entwickelt werden. Die Schneidstoffe sind abgestimmt auf Entwicklungen der Industrie, die Ventilsitzringe durch Verwendung neuer Materialien noch verschleißfester zu machen. Das robuste Spannsystem resultiert in einem maximalen Kraftschluss und somit einer homogenen Kraftverteilung im Plattensitz.
Die Weiterentwicklung von Verbrennungsmotoren hält trotz des eindeutigen Trends zur Elektromobilität an. Nicht zuletzt, um in modernen Hybridfahrzeugen genutzt zu werden. Als Technologiepartner steht MAPAL an der Seite der Kunden und trägt in kommenden Jahren dazu bei, deren Produktion weiter zu optimieren.
Contact
Mathias Ostertag Public Relations mathias.ostertag@mapal.com Phone: +49 7361 585 3566