内燃机

属于内燃机（ICE）领域的聚焦部件

气缸盖

气缸盖

在汽车领域，气缸盖通常由铝合金铸造而成，根据发动机燃料的不同，其结构和需要加工的特征也略有不同。它安装在气缸曲轴箱上，负责燃料和新鲜空气的供应。由于对质量和公差的要求极高，气缸盖是发动机生产中加工要求最高的组件。通过气门传动机构中精确的气门控制和凸轮轴轴承中最小的摩擦损失，甚至在燃烧过程开始之前就降低了油耗，从而减少了排放。 

亮点加工： 

• 气门传动机构 
• 喷油器内孔 
• 凸轮轴轴承孔 
• 平面铣削 
• 火花塞内孔 

气缸曲轴箱

气缸曲轴箱

气缸曲轴箱（又称为发动机缸体）是每台内燃机的核心部件。根据车型和发动机大小的不同，有各种不同的设计和尺寸，从2缸直列发动机到12缸V型排列发动机。由于铝合金具有重量轻的优势，目前主要用于汽车行业。这就迫使汽车制造商使用铸铁内衬或耐磨涂层，特别是在气缸内孔，以保证高里程数。因此，刀具制造商在切削加工过程中越来越多地遇到混合加工或极度磨蚀性涂层的情况。现代发动机燃烧压力的增加也提高了对机械和热负荷的要求，从而导致对加工特征的质量要求不断提高。  

亮点加工： 

• 气缸孔 
• 曲轴轴承孔 
• 珩磨所需的间隙 

连杆

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

Turbocharger

To increase the efficiency and performance of modern combustion engines, exhaust gas turbochargers are increasingly being used today. The compressed air supply via the turbocharger increases the efficiency of engines and at the same time reduces emissions. At speeds of up to 300,0001 rpm, it is imperative that quality requirements are met, especially with regard to coaxiality and roundness. Extremely abrasive high-alloy materials, especially on the exhaust gas side (turbine side), demand maximum wear resistance from the cutting tools. If the tool life quantities for the various machining operations are increased by even just a few components, this has an enormous cost benefit for the manufacturer.

Highlight machining:

• Turbocharger housing connection surface
• Turbine housing
• Control pin bore
• Turbine inner contour & V-band
• Connection machining

Rocker/toggle lever

Rocker/toggle lever

The high-precision control of the valves for intake and exhaust is a decisive factor for the performance and efficiency of combustion engines. 4 valves per cylinder are usually controlled in the automotive sector, with 2 valves controlling the intake for fresh air or air/fuel mixture and 2 valves controlling the exhaust gas outlet. Depending on the engine design, various rocker arms or (roller) finger followers are used for OHV and SOHC valve actuation in order to minimize friction and the associated wear on the moving parts. In addition, the valve clearance can be set and readjusted via the integrated adjusting disks in order to maintain an optimum combustion process and prevent possible engine damage. 

Highlight machining:

• Bearing bore
• Fitting bore

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