2 Crankshafts
2 Turning of crankshafts
3 Wiper inserts
3 Thrust Bearings
4 Main Bearings
7 Milling of crankshafts
12 Milling of camshafts
15 Cutting sequence
16 Further information
Crankshafts
Crankshafts are common machine elements which transfer
rotational movement into linear. Crankshaft design in
modern internal combustion engines is driven by the de-
sire for more power at higher efficiency rates and reduced
weight.
Turning of crankshafts
Flange - Stub end
Turning of crankshafts in mass production is still a very
popular method of machining. It dominates for the ma-
chining of both flange and stub end but can, in many
cases, also turn the number one main bearing.
2
One of the first operations on a crankshaft is the prepara-
tion of flange and stub end, so that they can be used for
clamping purposes in further operations.
Wiper inserts
Wiper inserts are innovative high-produc- Standard corner radius
Wiper radius
Thrust Bearings
Back turning of the thrust bearing is one
of the last chip forming operations during
the production of crankshafts. Best re-
sults are obtained with Coro Turn 107
Wiper inserts in adjustable tool holders.
3
45 1
2
3
Main Bearings
The machining of main bearings is done on special crank-
shaft Turning- or Turn-Turn- Broach centres. These ma-
chines are equipped with two, disk like turrets, each hold-
ing 45 insert-carrying cassettes.
4
Turning or
Turn- Broaching
Two different methods can be used for the finishing of the Turning
bearing diameters. When Turn- Broaching is applied, a
broaching insert mounted in a cassette is fed tangentially
along the surface to be finished .
Turn Broaching
5
Coromant Grades
Turn- Broaching and
Turning inserts for P M K
Crankshaft Machining HC HC HC HC HC
4015
2015
4025
2025
3005
3025
Engineered solutions
Please inquire for
further grades
341.G.540-214 L 465
and dimensions.
341.G.540-591 L 465
341.G.540-450 L 465
CAPP- solutions
S-CNMU 120412-KM
120412-PM
120412-QM 567SA
S-TNMU 160412-KM
160412-WM
S-WNMU 080412-KM
080412-WM 1525
S-SNMU 120416-KM
341.G.RNMU-001
S-CNMT 120412-MR
S-RCMX 1204MO-KH
For VBMT + DCMT Standard inserts see our Turning tools catalogue 2002 (C-1000:8)
6
Milling of crankshafts
Internal Milling of
crankshafts
Crankshaft machining with ring-shaped milling
cutters, having their inserts positioned internally,
is referred to as: "Internal Milling", "Whirling"
or "Planetary Milling".
Sandvik Coromant has built many of these cut-
ters over the years, and most of them have been
installed in production lines for truck crank-
shafts. They not only mill crank pins and
main journals, but also external web
shapes and flange diameters.
7
External Milling
of crankshafts
100 years of car production also means 100 years of
crankshaft mass production. The machining technology
involved, always determined by the current "state of the
art", has undergone multiple changes over those years.
The cutting feed and speed can be adjusted for the respec-
tive pin position to achieve the correct chip thickness and
a well balanced cutting force. Depending on the contact
zone, the cutting speed can reach 300 m/min which, in
combination with a well-selected feed, leads to extremely
short machining times.
Milling inserts
8
Roughing
The insert layout of Sandvik milling cutters corresponds Roughing
to the crankshaft profile to be milled. Depending on the segment
operations, we offer roughing cutters with a premilling
contour, and finishing cutters with an end profile contour
including the radial undercuts.
Finishing
Through the relationship of the large cutter; the small Finishing
workpiece diameter, the high number of inserts, and well segment
suited carbide grades, extremely long tool life can be
achieved.
Finishing
profile
9
A new approach for better
crankshaft quality
Surface quality
The cutting forces, created by the tangentially positioned
inserts, influenced the surface quality produced by the lat-
eral positioned inserts, which are working at the same
time on the oil collar faces. Also the roughing cutter, per-
forming on another part of the crankshaft simultaneously
with the finishing cutter, affects the surface quality of the
finishing operation by way of its cutting forces.
10
Insert layout and cutting sequence
Conventional version
Adjustable Fixed pocket
insert design design
New version
time, two shift production conditions. This application
has now been repeated constantly for the past year.
11
Milling of camshafts
Variable valve timing is a recently developed technology
which improves fuel economy and exhaust emissions. It
also shows that even after many decades of valve and
camshaft usage there is still room for improvements, a
principle which is also valid for camshaft production.
12
Milling Cutter Profiles
Cam Profiles
13
Based on our experience, and the long hours we spent
with our customers in their workshops, we know how the
ideal tool should look like from a customer perspective:
Cutter design
The cutter design and the insert layout of the lobe milling
cutters shown on these next two pages fit perfectly into
those customer demands.
Cutting
Only one type of insert, for lobe milling as well as for insert
chamfering, with 4 main and 8 chamfering cutting edges,
keeps the inventory and the carbide cost per part low and
creates no confusion when changing the inserts.
2 3
Segment 1 4
14
Cutting sequence
lateral radial
location orientation
cut 1
cut 2
cut 3
cut 4
cut 5
cut 6
= Steady Rest
= Cutter position
To avoid this the milling cutters were built with some ex-
tra mass to create a flywheel-effect in order to stabilise the
cutting action for longer tool life, better surface quality
and lower noise level.
15
Further information
For more information, or a quotation, on the Sandvik
crankshaft or camshaft tools, please contact your
nearest Sandvik office or the Centre of Competence as
listed below. To be able to prepare a complete quotation
the following information must be provided:
Drawings of workpiece with dimensions of
the blank and the final profile.
Information on the machine type and most
important, details of tool mounting
situation.
16
Sandvik Coromant
Center of Competence
Heerdter Landstr. 229-243
DE - 40549 Dsseldorf
Tel: 0049 (0) 211 - 5027 - 303
Fax: 0049 (0) 211 - 5027 - 103
www.sandvik.com