Reliable and Cost-effective Manufacture of Turbochargers in Series
The turbocharger has been state-of-the-art in diesel vehicles for some time. And almost all automotive manufacturers offer a turbocharged petrol engine. Why? The turbocharger makes comparable performance with a smaller engine capacity possible and that contributes to the advance in downsizing. Turbochargers also help to achieve lower fuel consumption and are therefore fundamental in meeting strict emission limits. MAPAL offers the complete process for machining these parts, including tools.
Challenge for machining tools
Most turbochargers are exhaust gas turbochargers. These look different at almost every automotive manufacturer and have a special geometry. Common to all: there are very high temperatures when they are used in vehicles with petrol engines. For this reason the turbine housing, the so-called “hot side” is manufactured from very abrasive, heat-resistant materials. These materials represent a particular challenge for every machining tool.
MAPAL has taken up these challenges and developed new cutting materials and tools. The company offers the complete process for machining turbochargers, including all tools, for example drills, milling cutters, reamers and mechatronic actuating tools – matched to the related geometry of the turbocharger. The company also assists its customers during the continuous further development of processes, to reduce cycle times and to increase tool lives. As such, combination tools that undertake multiple machining operations in one machining step form part of the portfolio.
A large part of turbocharger machining can be implemented using tools with ISO indexable inserts. Including many machining processes on the challenging hot side. MAPAL has developed a cutting material specially matched to the machining of heat-resistant cast steel and that offers long tool lives and therefore high cost-effectiveness, despite the abrasiveness of the material.
1. Complex boring tool with ISO indexable inserts
A particular challenge during the machining of the turbine housing for exhaust gas turbochargers is the main turbine bore. Its manufacture is subject to close tolerances in relation to shape, position and surface finish. The bore is bell-mouthed shaped to generate the best possible flow characteristics. MAPAL undertakes this machining operation using TOOLTRONIC with the LAT attachment (linear actuating tool). TOOLTRONIC, a mechatronic tool system, is a full NC axis integrated into the existing machine controller. The mounting tool is fitted with three inserts, one for roughing and two for finishing.
2. Turning on the machining centre using TOOLTRONIC
A particular challenge during the machining of the turbine housing for exhaust gas turbochargers is the main turbine bore. Its manufacture is subject to close tolerances in relation to shape, position and surface finish. The bore is bell-mouthed shaped to generate the best possible flow characteristics. MAPAL undertakes this machining operation using TOOLTRONIC with the LAT attachment (linear actuating tool). TOOLTRONIC, a mechatronic tool system, is a full NC axis integrated into the existing machine controller. The mounting tool is fitted with three inserts, one for roughing and two for finishing.
Machining example:
Material: 1.4837 | Cooling: MQL | Diameter: 40.5-57.295 mm | Cutting speed: 140 m/min (roughing), 120 m/min (finishing) | Feed: 0.15-0.4 mm | Tool life: 50 parts
Turning on the machining centre using TOOLTRONIC
3. Neuer Planfräser für die Schruppbearbeitung
Zum Schruppen der Planfläche des Turboladergehäuses eignet sich ein neuer, besonders wirtschaftlicher Fräser von MAPAL. Er stammt aus dem neuen Fräsprogramm mit gepressten, radialen ISO-Wendeschneidplatten, das MAPAL jüngst vorgestellt hat. Highlight dieses Planfräsers sind die ISO-Wendeschneidplatten mit 16 nutzbaren Schneidkanten. Damit ist der Einsatz des Werkzeugs besonders wirtschaftlich.
Ebenfalls besonders wirtschaftlich für Zerspaner ist das neue Werkzeug zur Vorbearbeitung des Katflanschs. Bei diesem Überdrehwerkzeug kommt die Tangentialtechnologie zum Einsatz. Durch den stehenden und liegenden Einbau der LTHU-Schneiden können effektiv acht Schneidkanten pro Wendeschneidplatte genutzt werden.
Die vier vorgestellten Werkzeuge zeigen zum einen die unterschiedlichen anfallenden Zerspanungsaufgaben am Turbolader, zum anderen stehen sie exemplarisch für die Werkzeugvielfalt und das Prozess-Know-how von MAPAL. Von Standardfräsern über mechatronische Aussteuerwerkzeuge bis zu komplexen Aufbohrwerkzeugen erhalten Zerspaner von MAPAL das komplette Programm mit Werkzeugen und Spannmitteln, die sie zur Bearbeitung von Turboladern benötigen. Dabei legt MAPAL den Gesamtprozess der Zerspanung so aus, dass Kunden die wirtschaftlichste und prozesssicherste Strategie nutzen. Immer im Blick: Genauigkeit bis auf den µm, damit die Turbolader im Einsatz höchste Effizienz erreichen.
