Crankshaft machining

EN
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CERATIZIT - secrets of success
The views and focus of our business
partners matter
Innovative and flexible
thinking matters
Communication matters
Employee development
matters
Our environment
matters
Secrets of success
Corporate values
Tailored cutting tool solutions
Professionalism matters
CERATIZIT is your partner for exceptional hard
material solutions. Hard materials and tools
from CERATIZIT - our solutions to complex
problems are an integral part of our customers
success. Our products guarantee: economy -
long life - speed! And it is precisely this
combination which gives our business partners
a direct competitive advantage.
Premier performance is only possible through
a total appreciation of the requirements of our
business partners. A performance achieved
through flexible thinking and continuous
dialogue with our customers. A pioneering
spirit and a deep understanding of powder
metallurgy characterize the history of
CERATIZIT. One of the attributes of our
company philosophy is the search for
perfection: target oriented - sustainably -
passionately!
Intensive research and development activities,
taking into account the precise requirements
and working processes of the customer,
are todays investment for the solutions of
tomorrow - and beyond.
Cutting materials, coatings, inserts, tooling
systems and machining solutions - all this is
included in the cutting tool division at
CERATIZIT.
Worldwide well-known companies process
advanced materials applying cutting tool
products from CERATIZIT: from the automotive


industry to the aerospace industry, mechanical
engineering, and tool construction to the oil
industry.
The basis of these long-term business relations
is the faith of the customers in the extensive
know-how of the carbide specialists.
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Crankshaft machining
External milling, internal milling, turning, turn-turn-broaching, broaching.
HyperCoat carbides and an optimized cutting edge system make the difference.
CERATIZIT carbides and tooling solutions have been applied in batch production by
well-known crankshaft manufacturers for many years.
Car crankshafts
Truck crankshafts
Large crankshafts for generators and marine engines
Materials:
Alloyed steel
Spheroidal cast iron
Modern cast iron types such as CGI and ADI
No. 1 in powder metallurgy
High level of vertical integration from the raw material to the finished insert
Over 30 years of experience in crankshaft machining
Everything from one source
Durable tools
Reliable cutting materials
Simple tool handling
Distinguishing features
The views and focus of our business partners matter
Instead of talking product with customers, we work on real
solutions for business partners.
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www.e-techstore.com
www.ceratizit.com
Specific team for OEM services to guarantee professional project processing
Close cooperation with machine manufacturers
Complete machining concepts and tooling solutions: workflow, tools, cutting
parameters, necessary tools, process times, process costs
Tooling Academy in Reutte supports process optimization
Support for acceptance and commissioning runs
Detailed project documentation
Worldwide distribution and service network
CERATIZIT not only offers you excellent cutting tools but also customized complete
solutions for optimal machining of your work pieces on new projects.
CERATIZIT service
Up-to-the-minute CERATIZIT product catalogue
including all technical details
Live-availability check for more than 20,000
standard articles
Easy and quick processing
More than 100,000 possibilities of tool
combinations online
Access 24 hours a day
Shipment tracking via Internet
(Track & Trace)
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Tools for crankshaft machining
Maximum performance capacity of the cutting materials combined with the
high-quality CERATIZIT tools ensures economic production.
CERATIZIT is your partner in crankshaft machining as a full-range supplier.
End-hole and counter-bore (2)
applying MaxiDrill, High Feed Drill and
EcoCut tools
Spigot and journal
machining (3)
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Machining of thrust faces (7)
Milling ends (1)
with MaxiMill tools
External milling (4) Internal milling (5) Turn-turn-broaching (6)
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Machining steps
16 cutting edges
Double-sided insert with positive rake and
clearance reduced cutting forces
Close pitch maximum economy, reduced
cycle time
HyperCoat grades for cast iron and steel
Very good surface quality
MaxiMill A273
Centre drills
Step drills
Carbide drills
High-performance insert drill
4 usable cutting edges
MaxiDrill HFD
Suitable for universal application
Optimum force compensation for drilling without deviation
MaxiDrill Classic
Drilling and turning with only one tool
Diameter 4 mm and greater
EcoCut
2) End-hole and counter-bore
1) Milling ends
see also brochures No. 505,
MaxiMill 181 and No. 181, EcoCut
see also brochure No. 467,
MaxiMill 273
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Machining steps
Customized tooling systems
MaxiLock D insert clamping
ISO turning inserts
MSS parting and grooving program
Adapters
HSK-T
CAPTO
Standard adapters
Turning tools
Optimized cycle time
Easy handling
Ideal for rough machining
Overturning tool
3) Spigot, flange and end-journal machining
see also brochures No. 148,
MaxiMill 512 and No. 512, HSK-T
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Machining steps
High metal removal rate
High process security
Maximum stability
Suitable for difficult conditions
Flexible thanks to cassettes
Upon request pre-set with shims
Setting mechanism available
Application: machining of main and pin bearings
Advantages
5) Internal milling
4) External milling
Long intervals between tool changes
High cutting speed
External machining of webs
Flexible thanks to cassettes
Upon request pre-set with shims
Setting mechanism available
Application: machining of main and pin bearings
Advantages
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2
3
Milling innovations
NEWS:
Axial run-out within 0.005 mm
For maximum surface quality and
geometric accuracy
Adjustable tools
High precision without setting
Radial and axial run-out within 0.025 mm
Shims
Insert clamping with precise repeatability
for cutting edges
Insert seat design clearance
Stable
User-friendly
Precise repeatability
Cassette clamping system X-Lock
Cutting speed 4501000 m/min
Cycle time reduced by 50%
High-speed milling with ceramic inserts
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2
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Machining steps
Standard ISO inserts
MaxiLock D insert clamping
Inserts for broaching
Cassettes
Inserts for broaching
Minimized downtime = short chip to chip time
6) Turn-turn-broaching, broaching
7) Machining of thrust faces
CERMET
Carbide
CBN
Masterfinish inserts
Adjustable tooling systems
Everything from one source
Application: machining of main bearings
Advantages
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Special tools according to customers specifications
These tools have greatly improved productivity:
Talk to our technical experts. We will help you optimize the
machining of your component.
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Success stories
Criteria:
> Machining of 80% cast iron and 20% steel
crankshafts
> Swarf control for steel crankshafts
> Tool life when cast iron machining
> Tolerance of undercut radius
Result:
> Optimized swarf control
> Tool life increased by 50%
> Undercut radius within tolerance
(criterion for release)
Technical data:
Work piece: crankshaft machining
Material: GGG-60 (80%) / steel (20%)
Hardness: 250 HB (cast iron) / machined surface
Machine: Boehringer
Tool: turn-turn-broach disc
Insert: Z 10005007-0
Grade: 1002 (hard metal, CVD coated)
Cutting data:
> CERATIZIT
v
c
= 180 m/min
a
p
= 2 mm
f = 0.31 mm
dry
> Competitor
v
c
= 180 m/min
a
p
= 2 mm
f = 0.31 mm
dry
Criteria:
> Tool life
> Surface finish
> Dimensional accuracy
Result:
> Tool life increased by 18%
> Cost per part reduced by 25%
> Component quality guaranteed
Technical data:
Work piece: 5-cylinder crankshaft
Material: GGG-60
Tensile strength: 650 N/m
2
Machine: Boehringer
Tool: side and face milling cutter 700 mm
Insert: Z10007823-0
Grade: 1066 (hard metal, PVD coated)
Cutting data:
> CERATIZIT
v
c
= 200 m/min
a
p
= 3.5 mm
h
max
= 0.23 mm
dry
> Competitor
v
c
= 200 m/min
a
p
= 3.5 mm
h
max
= 0.23 mm
dry
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Success stories
Criteria:
> Surface finish
> Swarf control
> Dimensional accuracy
> Cycle time
Result:
> No interruption of production caused by
lack of swarf control
> Tool life increased by 50%
> No surface damage caused by
lack of swarf control
> Process security guaranteed
Technical data:
Work piece: crankshaft (end machining)
Material: 38 CrMnMoS 6
Tensile strength: 1100 1200 N/m
2
Machine: Edschede transfer line
Tool: special tool
Insert: TNMG 160408EN-TMF
Grade: CTC1115
Cutting data:
> CERATIZIT
v
c
= 84 m/min
a
p
= 1 2 mm
f
z
= 0.8 mm
dry
> Competitor
v
c
= 84 m/min
a
p
= 1 2 mm
f
z
= 0.18 mm
dry
Criteria:
> Cycle time
> Surfac finish
> Cutting force
Result:
> Cassette types reduced from 6 to 2
reduced stock keeping
> Number of cutting edges increased by 50%
> Feed rate increased by 50%
> Increased number of usable cutting edges per
insert
Technical data:
Work piece: large crankshaft
Material: 34CrNiMo6
Tensile strength: > 950 N/m
2
Machine: Niles N42 C
Tool: side and face milling cutter 660 mm
Insert: special insert
Grade: 1112 (hard metal, PVD coated)
Cutting data:
> CERATIZIT
v
c
= 176 m/min
a
p
= 8 mm
f = 0.29 mm
dry
> Competitor
v
c
= 176 m/min
a
p
= 8 mm
f = 0.29mm
dry
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Machining sketch
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www.ceratizit.com
CERATIZIT worldwide
Production sites in the three big economic
areas with a worldwide network of CERATIZIT
sales and support engineers plus many
CERATIZIT distribution partners guarantee
customer vicinity.

We maintain the dialogue with our customers
and strive for long-term partnerships.
CERATIZIT worldwide production sites and support centres
CERATIZIT worldwide sales centres
CERATIZIT worldwide distribution partner network
Parent company in
Luxembourg
CERATIZIT Luxembourg Srl
Route de Holzem 101
L-8232 Mamer
Tel.: +352 312 085-1
Fax: +352 311 911
E-mail: info@ceratizit.com
www.ceratizit.com
CERATIZIT worldwide
CERATIZIT worldwide
Find your personal distribution partner at:
Contact for further information:
CERATIZIT Austria Gesellschaft m.b.H.
A-6600 Reutte/Tyrol
Tel.: +43 (5672) 200-0
Fax: +43 (5672) 200-502
E-mail: info.austria@ceratizit.com
www.ceratizit.com
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