Zerspanungslösungen für Verbrennungsmotoren

Fokuskomponenten aus dem Bereich ICE

Zylinderkopf

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

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Zylinderkurbelgehäuse

Bloc-cylindres

Le bloc-cylindres, ou encore bloc-moteur, est l'élément central de tout moteur à combustion. En fonction du modèle de véhicule et de la taille du moteur, il existe une multitude de types et de tailles différents, du moteur 2 cylindres en ligne à la disposition 12 cylindres en V. En raison de leur poids avantageux, les alliages d'aluminium sont aujourd'hui principalement utilisés dans le secteur automobile. De ce fait, les constructeurs automobiles sont obligés d'utiliser des douilles en fonte ou des revêtements résistants à l'usure, spécialement pour l'alésage des cylindres, afin de garantir un kilométrage élevé. En conséquence, les fabricants d'outils sont de plus en plus souvent confrontés à des usinages multiples ou à des revêtements abrasifs lors de l'usinage. Les pressions de combustion plus élevées des moteurs modernes augmentent également les contraintes de charge mécanique et thermique, ce qui implique entre autres des exigences de qualité croissantes concernant les caractéristiques à usiner. 

Principaux usinages : 

• Alésage de cylindre 
• Alésage de palier de vilebrequin 
• Pierrage 

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Bielle

Bielle

Pour les bielles motrices soumises à de fortes contraintes variables, des matériaux en acier à haute résistance comme le 70MnVS4 ou le C70 sont utilisés. Le mouvement linéaire des pistons est transformé en un mouvement de rotation du vilebrequin. Afin de réduire la masse en mouvement pendant le fonctionnement du moteur, le poids des composants est réduit au minimum. Au fil des ans, une vaste diversité de variantes s'est développée, avec par exemple des formes parallèles, trapézoïdales ou étagées, qui entraînent les situations d'usinage les plus diverses, notamment pour l'usinage du petit œil de bielle. En raison de la très grande quantité de pièces produites, les fabricants se concentrent particulièrement sur la rentabilité dans la production en série. 

Principaux usinages : 

• Grand œil 
• Petit œil 
• Alésage de trou de vis 

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Turbocompresseur

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

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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

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Rail

Rail

Conosciuto come common rail nei motori diesel, ora il carburante viene iniettato nella camera di combustione anche di un’auto a benzina su due, attraverso efficienti sistemi di iniezione diretta. La miscela aria-carburante si forma dapprima nella camera di combustione. Ciò garantisce motori a benzina più potenti con consumi ridotti e minori emissioni di scarico. I crescenti requisiti di pressione fino a 2.500 bar sono decisivi per l’utilizzo di materiali che presentano difficoltà di lavorazione moderata e complessa come l’acciaio fuso o l’acciaio inossidabile.

Lavorazioni principali: 

• Foro centrale del rail 
• Foro dell’iniettore / trasferimento iniettore 
• Collegamento ad alta pressione 
• Lavorazione delle estremità

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Albero a gomiti

Albero a gomiti

La forma base dell’albero a gomiti è determinata principalmente dal numero di cilindri e dalla variante del motore. Tuttavia, gli alberi, per lo più in acciaio forgiato, devono diventare sempre più leggeri per ridurre le emissioni. Ciò significa che sono necessarie ulteriori lavorazioni nella produzione di componenti già complessi. Inoltre, a causa delle crescenti pressioni di combustione dei motori moderni, l’albero a gomiti è costantemente esposto a maggiori sollecitazioni di flessione e torsione, con conseguenti requisiti di qualità superiori.

Lavorazioni principali: 

• Foro centrale di alleggerimento 
• Foro del canale dell’olio 
• Lavorazione delle estremità

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Face and sealing surfaces

Face and sealing surfaces

Machining flat sealing surfaces in the combustion engine requires the utmost in dimensional accuracy, flatness and surface quality – often in dry conditions. MAPAL supplies high-performance face milling tools with maximum number of teeth, sturdy tool design and optimal chip removal. Whether roughing or finishing: The solutions are designed for cost-effectiveness, process reliability and component quality.

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