EMAG CRANKSHAFT GRINDING MACHINES More than just machines - systems designed by EMAG experts
AUTOMOTIVE CRANKSHAFTS Automotive crankshafts come in a wide variety of sizes, shapes and manufacturing types. Starting from small 0.8 liter two-cylinder engines and the conventional four-cylinder engine used in mid-range models, to large twelve-cylinder engines. The majority of these crankshafts are either cast or forged, with cast versions being particularly popular for large quantities and low performance engines. Forged crankshafts and even assembled crankshafts made of stainless steel are primarily used in the premium sector as a result of their higher vibration resistance and generally higher load capacity.
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MACHINING CRANKSHAFTS WITH EMAG I Automotive Crankshafts
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PRODUCTIVE GRINDING OF AUTOMOTIVE CRANKSHAFTS This example shows the productive machining configuration of an automotive crankshaft in three operations. In OP 80, the main and pin bearings are pre-ground by a PMD 2, a crankshaft grinding machine with two grinding spindles. The finish grinding of the main and pin bearings takes place in OP 90 on a second PMD 2.
MACHINING A VARIETY OF CRANKSHAFTS FROM A TWOCYLINDER SHAFT TO A V8 SHAFT ++ 30 kW (40 hp) motor spindles for grinding wheel (optional: 40 kW (54 hp))
++ Direct drive spindle ++ Grinding with CBN grinding wheels (aluminum oxide available)
++ Oscillating stroke grinding of lifting bearings with the workpieces centrally clamped
++ Maximize productivity by simultaneously grinding using independent grinding spindles
++ Absolute measuring systems on X- and Z-axes ++ Hydrostatic guideways and anti-backlash linear motor (X-axis)
++ In-process measurement control systems ++ Integrated roundness check and roundness correction ++ Automatic self-centering steady rests ++ Axial and radial alignment using a programmable probe ++ EMAG programming system ++ SIEMENS 840 D Solution Line Hydrostatic guide track and backlash free linear motor (X-axis)
OP 80 + OP 90 PMD 2: PRE-GRINDING + FINISH GRINDING
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Pre-grinding the main and pin bearings
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Finish grinding the main and pin bearings
Headstock
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Tailstock
In this example, the HG 208 is equiped with a center drive and a B-axis, and along with a third grinding spindle.
HG 208 B CD CENTER DRIVE GRINDING MACHINE Machine and equipment details:
++ Grinding with CBN grinding wheels (aluminum oxide possible)
++ Workpiece clamping between centers ++ Grinding wheel with integrated motor spindle ++ Workpiece drive using center drive unit ++ Absolute measuring systems on X- and Z-axes ++ In-process measuring control for external diameter and bearing width
++ B-axis with two grinding spindles ++ EMAG programming system ++ SIEMENS 840 D Solution Line
Linear guides and ball screws on the X- and Z-axes
CRANKSHAFT MACHINING WITH EMAG I Grinding of Automotive Crankshafts
The flange, post end and thrust bearing shoulders are then finish-ground in a single clamping on an HG 208 B CD.
OP 120 HG 208 B CD: FINISH GRINDING
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rinding the flange and G post end simultaneously
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Indexing the B-axis
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rinding both thrust bearing G shoulders in sequence
Tailstock
Center drive
Tailstock
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ADDITIONAL B-AXIS FOR INCREASED FLEXIBILITY To make the machines process design as flexible as possible, the PMD series can also be equipped with one or two B-axes in the compound slide. This makes it possible for additional operations such as grinding the gear seat, flange, journal, and shoulders or pre-grinding and finish grinding can all be performed in single clamping operation.
PMD 2 B, twin-slide machine with B-axis
PMD 2 B: PRE-GRINDING
Headstock
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PMD 2 B, twin-slide machine with two B-axes
PMD 2 B: FINISH GRINDING
Tailstock
Headstock
Tailstock
» Clamping on the flange diameter
» Index the B-axes
» Grinding the main and pin bearings
» Finish grinding the main and pin bearings
ADDITIONAL APPLICATION FOR HG MACHINES FOR CRANKSHAFT MACHINING HG 208 ANGLE PLUNGE GRINDING MACHINE WITH INTERNAL GRINDING SPINDLE Machine and equipment details:
++ Grinding with CBN grinding wheels ++ Workpiece clamping using chuck + steady rest ++ Motor spindle for internal and external grinding
HG 208 i:
SIMULTANEOUS MACHINING OF FLANGE AND INTERNAL DIAMETER
++ Separate cross slides for external and internal machining
++ Linear guides on X- and Z-axes ++ Ball screw for X- and Z-axes ++ Absolute measuring systems on X- and Z-axes ++ In-process measuring control for external and internal grinding
++ EMAG programming system ++ SIEMENS 840 D Solution Line
PMD 2 B
CRANKSHAFT GRINDING MACHINE Machine and equipment details:
++ Machining with up to four grinding wheels ++ Third and fourth wheels are replacement tools ++ Significant reduction in retooling times ++ Machining multiple operations in a single clamping cycle
Headstock
Internal grinding spindle
CRANKSHAFT MACHINING WITH EMAG I Additional B-axis for Improved Flexibility | Additional Application for HG Machines
The HG Series can be equiped with a range of options. In this example, the tailstock is replaced by an internal grinding spindle which allows the parallel machining of the flange profile and the needle roller bearing borehole.
»» Simultaneous grinding of the flange profile and the internal diameter
»» Perfect clamping using a steady rest »» In-process measurement of internal and external diameter
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CRANKSHAFTS FOR SMALL ENGINES Scooters, lawnmowers, or generators generally have single- or two-cylinder engines. Probably the most well known and best-selling model of this type of engine is the 50Â cc two-stroke internal combustion engine, which is featured in millions of motorcycles. Almost all of the miniature tractors and lawnmowers available on the market also feature single-cylinder engines. The more powerful models use engines with a displacement of up to two liters, which can develop up to 75Â bhp.
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CRANKSHAFT MACHINING WITH EMAG I Crankshafts for Small Engines
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COMPLETE MACHINING IN A SINGLE CLAMPING OPERATION Standard configuration of the machining area Two cross slides with grinding spindles for the external grinding of the main and pin bearings Headstock with chuck for clamping on the external diameter Tailstock with center point
The machine has been equiped with two headstocks for the complete machining of a crankshaft in a single clamping operation. This allows the alternate clamping of the crankshaft on the flange and on the journal side. Both chucks with retractable jaws and a face driver are used for this purpose.
MACHINING STEP 1: CLAMPING LEFT
Headstock 1
MACHININ CLAMPIN
Headstock 2
Headstock 1
Clamping left
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»» Clamping on the flange diameter
»» Reclamping on the journal side
»» Grinding the main and pin bearings
»» Chuck with retractable jaws
Only the ability to install two workpiece headstocks on the PMD 2 makes the complete machining in a single clamping operation possible. This enables the PMD 2 to play to its strengths with the flexible design of the machining area.
NG STEP 2: NG RIGHT
MACHINING STEP 3: FACE DRIVER LEFT
Headstock 2
Clamping right
»» Grinding flange and main bearings
Headstock 1
CRANKSHAFT MACHINING WITH EMAG I Complete Machining in a Single Clamping Operation
The particular challenge for the complete machining of a crankshaft in a single clamping operation is the design of the workpiece clamping system.
Headstock 2
Cam left
»» Drive with front face driver »» Grinding the journal
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TRUCK CRANKSHAFTS Truck crankshafts are designed to provide high performance at low speeds. Trucks have five or six-cylinder engines with a displacement of 7 – 13 liters (2 - 3 gal). In the higher performance classes, they may even have a displacement of up to 16 liters (4 gal) and eight cylinders. The high forces that act on the crankshaft, combined with the long service life expected from truck engines, make the production of these components particularly demanding. This component is not just challenging as a result of its dimensions and weight but also due to the high level of precision required for grinding the crankshaft. EMAG’s PM Series delivers a range of benefits in this respect.
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CRANKSHAFT MACHINING WITH EMAG I Truck Crankshafts
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MACHINING TRUCK CRANKSHAFTS WITH THE PM 320 / PMD 320 A wide range of machine versions can be configured with the modular machine system of the PM 320 / PMD 320 to fit the manufacturing task. Whether it is grinding of the main and pin bearing on the same machine in a single clamping or on separate machines using the traditional method, depends on the production requirements.
Tailstock
Headstock
AVAILABLE MACHINING TECHNOLOGIES PLUNGE GRINDING
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MULTIPLE PLUNGE GRINDING
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++ CBN technology also for grinding with radii and shoulders
++ Pin chasing grinding of the pin bearings with the workpieces centrally clamped
++ Maximize productivity by simultaneously grinding using independent grinding spindles
++ X-axis drive system with anti-backlash linear motor ++ Workpiece headstock with direct drive ++ Hydrostatic guideways (X- and Z-axes) ++ In-process measurement control systems ++ Grinding spindle with integrated motor spindle ++ Integrated roundness check and roundness correction
++ Automatic self-centering steady rests ++ Axial and radial alignment using a programmable probe
++ EMAG programming system ++ SIEMENS 840 D Solution Line
DIAGONAL GRINDING
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CRANKSHAFT MACHINING WITH EMAG I Machining Truck Crankshafts with the PM 320 / PMD 320
SPECIAL FEATURES OF THE PM 320 / PMD 320:
FLEXIBLE PROCESS
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CRANKSHAFTS FOR SHIP ENGINES Shafts for ship diesel engines are a little bit larger than crankshafts for trucks. Crankshafts, which are typically ground on EMAG PM Series machines, are used in yachts, ferries, or even cargo ships. Ship engines, and therefore the crankshafts, are also intended for high performance at low speeds and require high precision in the production process, just like truck crankshafts.
Up to 8Â m (26 ft)
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CRANKSHAFT MACHINING WITH EMAG I Crankshafts for Ship Engines
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MACHINING LARGE CRANKSHAFTS WITH THE PM 430/PM 460/PM 480 The PM 4 Series is equiped with linear motors and hydrostatic guideways in the X- and Z-axes, which ensures maximum dynamics and excellent grinding results. The main and pin bearings are ground in a single clamping operation using conventional aluminum oxide or CBN grinding wheels. This ensures high productivity and flexibility, allowing grinding processes that are fully automatic, semi-automatic, or manual. The workpiece is driven on both sides by face driver or hydraulic chucks, depending on the task, and the workpiece spindle has a direct drive in the form of a torque motor. The grinding spindle itself is a motor spindle. If a higher torque is required, a separate motor with a belt transmission is available. The large automatic front doors, which provide excellent access to the machining area, and the easy-to-use control interface ensure highly productive manufacturing and fast workpiece changes.
Two Slides Optional
Headstock
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Tailstock
++ Pin chasing grinding of large crankshafts:
Grinding main and pin bearings on simple clamping
++ Use of conventional aluminum oxide grinding wheels or CBN grinding wheels
++ High productivity coupled with increased flexibility ++ Fully automatic, semi-automatic or manual grinding processes possible
++ In-process diameter measurement for maximum precision and roundness check in the machine
++ Universal axial and radial alignment of the shaft
before grinding to ensure top quality with maximum flexibility
++ Very rigid two-axis NC steady rests for excellent crankshaft support
CRANKSHAFT MACHINING WITH EMAG I Machining Large Crankshafts with the PM 430 / PM 460 / PM 480
MAIN FEATURES OF THE PM 430/PM 460/PM 480
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