Rail

Like in diesel engines with common rail systems, fuel is increasingly injected straight into the combustion chamber in modern petrol engines, too. The mixture formation takes place only in the combustion chamber, boosting performance and efficiency and reducing emissions. The increasing injection pressures of up to 2,500 bar set stringent requirements on components and
workpiece materials. Materials that are difficult to machine are used, such as cast steel or stainless steel – connected with complex machining processes.
Rail with high‑pressure port, injector bores and central bore

Key features

  1. High-pressure Connection
  2. Injector bore
  3. End machining
  4. Connection machining
  5. Centrail rail bore

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