The crankshaft itself is the weakest link in the process system consisting of machine tool-clamp-part-tools. The instability of the parts always affects the minimum process time and consistency of processing quality. This places high demands on the development and design of tools, inserts and corresponding application know-how. It means optimizing the distribution of the cutting edges to achieve cutting force balance, optimizing the cutting parameters for different types of surfaces, so that the cutting is smooth without vibration and so on.
To truly engage in the crankshaft processing business, you must have the appropriate background, capabilities and resources. Sandvik Coromant's professional center for crankshafts and camshaft machining is located in the heart of Europe, Germany, for this purpose. We have developed close and fruitful cooperation with many crankshaft manufacturers around the world and several professional crankshaft machine tool manufacturers.
Turning of the crankshaft This is a method for machining the main journal of a crankshaft with considerable flexibility. In some cases or in some places, it is also used for the processing of the connecting rod neck. If used to machine the connecting rod neck, the mass imbalance and the off-center clamping position require a special clamp with a balance weight. Turning is usually carried out on a crankshaft processing machine and a standard lathe equipped with a dedicated turret. Due to the large overhang of the tool and the tendency to vibrate, the requirements for the tool are very high.
Only a few machine tools are used in a limited range of crankshaft machining. This is a broaching process that allows for conventional linear broaching of a tangential feed of a rotating crankshaft by a linear pull method, or a rotary broach using a circular or spiral broach developed later. Although this method is very efficient, it has not been promoted so far because of its lack of flexibility.
The crank-car-car-pull processing car-car pull is a combination of turning and pulling. The turning and pulling tools are radially mounted on a circular cutter head, and the spindle neck or connecting rod neck of the rotating crankshaft is machined. The method is suitable for most types of crankshafts. The turning process is mainly roughing. At this time, the cutter head does not rotate and the cutting edge is at the center line of the workpiece. The pull tool is finished for cutting, and the cutter head is slowly rotated by rotating the main journal or the connecting rod neck surface of the rotating crankshaft. Processing to the move. The advantage of this method is that a large number of sister tools can be installed on the cutter head to balance tool life and extend tool change time.
Internal milling of the crankshaft Internal milling, also known as rotary milling or planetary milling, allows heavy-duty milling over long cutting times. The crankshaft passes through a rotating milling cutter. The indexable inserts are arranged on the inner circumference of the milling cutter to machine the main journal, the connecting rod neck and the side of the segment of the crankshaft. It is a very stable processing method, mainly used for large crankshafts, or when the blank margin is large.
The external milling of the crankshaft is mainly used for machining large and medium-sized automobile crankshafts in large quantities. It can be seen as a high-speed rotating dense-toothed three-face milling cutter that processes the surface of the workpiece in a slow-rotating motion of the crankshaft. The method is characterized by high metal removal rate and rapid cutting positioning. In general, an outer cutter with a diameter of 700 mm can be installed with up to 350 blades. It can machine the main journal of the crankshaft, the connecting rod neck and the side and outer faces of the segment. The method has a short process time and is very quick to change the knife.
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