Rail

Wie bei Dieselmotoren mit Common-Rail-Systemen wird auch bei modernen Ottomotoren der Kraftstoff zunehmend direkt in den Brennraum eingespritzt. Die Gemischbildung erfolgt dabei erst im Brennraum, was Leistung und Effizienz steigert und Emissionen reduziert. Die steigenden Einspritzdrücke von bis zu 2.500 bar stellen höchste Anforderungen an Bauteile und Werkstoffe. Zum Einsatz kommen schwer zerspanbare Materialien wie Stahlguss oder Edelstahl – verbunden mit komplexen Bearbeitungsprozessen.

PROCESS CONDITIONS

Extremely hard outer forging scale
Extreme drilling depths of up to 25xD
Diameter tolerances of 0.20 mm
Long chipping workpiece materials

1. High-pressure Connection

Tool for precision drilling of small holes for rail applications

Solid drills

Solid carbide drills for the smallest bore diameters.

2. Injector bore

Tool for precision finishing of injector bores with high dimensional and surface accuracy

Coated solid carbide step reamer

Special tool design for optimal cut Distribution and chip control at the step changes.

3. End machining

Face milling cutter for end machining of rail components

Face cutter head

Multi-blade combination tool for face milling and pre-grooving of the faceside chamfers.

4. Connection machining

Tool for machining diameters and chamfers on face surfaces

Face counterbore

Monolithic tool design with indexable inserts for machining diameter and chamfer.

5. Centrail rail bore

Pilot and deep drilling for central rail bores.

1. Pre-machining
Pilot drill

Special geometry for the outer forging scale that is difficult to machine, perfectly adapted to the subsequent deep-hole drill.

2. Drilling from solid
Deep drills

Optimised geometry and coating for maximum performance and optimal chip flow, including at extreme drilling depths