内燃エンジン

ICE分野の重点部品

シリンダヘッド

Cylinder head

In the passenger car sector, the cylinder head is usually cast from aluminum alloys, whereby the structure and the features to be machined differ slightly depending on the engine fuel. It is mounted on the cylinder crankcase and is primarily responsible for the fuel and fresh air supply. Due to its extremely high quality and tolerance requirements, the cylinder head is the most demanding component to be machined in engine production. Precise valve control in the valve train and minimal friction losses in the camshaft bearings reduce fuel consumption and thus emissions even before the combustion process begins.

Machining highlights:

• Valve train
• Injector bore
• Camshaft bearing bore
• Face milling
• Spark plug bore

Cylinder crankcase

Cylinder crankcase

The cylinder crankcase, also known as the engine block, is the central element of every combustion engine. Depending on the vehicle model and engine size, there are a variety of different designs and sizes, from 2-cylinder in-line engines to 12-cylinder V-arrangements. Due to the weight advantage, aluminum alloys are predominantly used in the automotive sector today. However, this forces car manufacturers to use cast liners or wear-resistant coatings, especially for cylinder bores, in order to guarantee a high mileage. During machining, tool manufacturers are increasingly encountering mixed machining (cast aluminum) or extremely abrasive coatings. The increased combustion pressures of modern engines also increase the mechanical and thermal load requirements, which, among other things, leads to increasing quality requirements for the features to be machined.

Highlight machining:

• Cylinder bore
• Crankshaft bearing bore
• Honing pass

Connecting rod

Connecting rod

High-strength steel materials such as 70MnVS4 or C70 are generally used for the connecting rods, which are subject to alternating heavy loads, in order to convert the linear movement of the pistons into a rotational movement of the crankshaft. In order to reduce the moving mass during engine operation, the components are reduced to a minimum weight. Over the years, this has resulted in an enormous number of variants with, for example, parallel, trapezoidal or stepped shapes, which entail a wide variety of tapping situations, especially when machining the small connecting rod eye. Due to the enormous production quantities, manufacturers are particularly focused on cost-effectiveness in series production.

Highlight machining:

• Large eye
• Small eye
• Screw hole drilling

Turbocharger

涡轮增压器

为了提高现代内燃机的效率和性能，废气涡轮增压器如今得到了越来越广泛的应用。通过涡轮增压器提供的压缩空气可提高发动机的效率，同时减少排放量。在转速高达 300,000 rpm 的情况下，必须满足质量要求，尤其是同轴度和圆度。极度磨蚀性的高合金材料，尤其是在废气侧的材料对于刀具设计，要求切削刀具具有最大的耐磨性。 若仅通过几个组件就能延长不同加工方式的刀具使用寿命，这对于制造商来说具有巨大的成本优势。  

亮点加工： 

• 轮增压器外壳连接面 
• 涡轮机壳体 
• 控制销孔 
• 涡轮内轮廓和V形边 
• 连接加工 

翻转杠杆/滞后杠杆

翻转杠杆/滞后杠杆

进气门和排气门的高精度控制对于内燃机的性能和效率非常重要。在汽车领域，每个气缸通常控制四个阀门，其中两个阀门控制新鲜空气或空气燃料混合物的入口，另外两个控制废气出口。根据发动机设计的不同，OHV 和 SOHC 阀门控制中使用不同的翻转杠杆或（滚子）滞后杠杆，以将活动部件的摩擦和相关磨损降至最低。此外，可以使用集成调节盘调节或重新调节气门间隙，以保证最佳的燃烧过程并防止可能的发动机损坏。 

亮点加工： 

• 轴承孔 
• 配合孔 

Rail

Rail

As in diesel engines known as common rail, fuel is now also injected into the combustion chamber of every second new petrol car via efficient direct injection systems, in which the air-fuel mixture is first formed in the combustion chamber. This enables more powerful petrol engines with reduced fuel consumption and lower exhaust emissions. The increasing pressure requirements of up to 2,500 bar are decisive for the use of moderately to difficult-to-machine materials such as cast steel or stainless steel.

Machining highlights:

• Central rail bore
• Injector bore / Injector transfer
• High pressure connection
• End machining

Crankshaft

Crankshaft

The basic design of the crankshaft is largely determined by the number of cylinders and the engine layout. However, the steel shafts, which are generally forged, have to be made lighter and lighter to reduce emissions. This means that additional machining operations are required in the manufacture of the already complex components. Furthermore, due to the increasing combustion pressures of modern engines, the crankshaft is constantly exposed to increased bending and torsional stresses, which results in higher quality requirements. 

Highlight machining:

• Central relief bore
• Oil channel bore
• End machining