CRANKSHAFT MACHINING

Solutions & Applications, Turning

, Milling

, Hobbing

, Grinding

, Honing

, Composites

, Systems Integration

, Automation & Software

, Services

, Tooling & Fluids

, Core Components

Crankshaft MachiningOur Expertise

02 | 03

The comprehensive range of equipment offered by MAG is designed to

perform most all of the rough-end operations on small car to large size

truck crankshafts, regardless whether these crankshafts are made of

cast iron or forged steel. Modular subassemblies, identical control and

drive concepts, as well as standardized HMIs significantly ease your daily

workload.

With over 90 years of experience in crankshaft machining, we provide

various levels of turnkey solutions, all precisely tailored to your specific

workpiece and individual needs. We accommodate challenging product

designs, production rates and flexibility requirements. Our focus targets all

parameters critical to successful manufacturing, such as workpiece quality,

process reliability, machine uptime, part piece and life cycle costs.

We challenge you to benefit from our vast experiences and to partner-up

with MAG for your next crankshaft program.

Part Range Crankshafts for

, For small cars / motorcycles

, Full to large size cars

, Light-duty trucks

, Medium to heavy duty trucks

, Other sizes / applicators on request

Your Advantage

, Uniform machine concept for the entire rough-end section

of the crankshaft line

, Our entire system and process know-how

, Single-source contact and responsibility for the entire supply content

, Uniform control and drive concepts for all machines

, Operator-friendly HMIs with communicative screen pictures tailored

specifically to crankshaft manufacturing, resulting in significantly

simplified machine operation

, Standardized subassemblies for quick and cost-effective maintenance,

as well as reduced spare parts inventory

, Broad product and technology spectrum delivering best-practice

approach for all applications

Technologies

, Cutting to length and centering

, Oil hole drilling

, Turning

, Roller burnishing

, Turn-turnbroaching

, High-speed external milling

, Hyper speed milling

Truck Competence

Requirements

, From small to mid-sized to large batches

, High surface qualities

, High cutting performance

Our Solution

, Indiviual machine generation for truck crankshafts

, Especially robust machine design

, Processing with two independent steady rests possible

, Special tooling and processing concepts

, Experience with imbalanced V shafts

, Processing of center and pin bearings in one setup

Your Advantages

, Productivity

, High flexibility

, Environmentally friendly

Demanding Applications for Heavy Industry

Industries

, Pump shafts

, Ship engine components

, Oil field crankshafts

, Off road

, Locomotives

, Stationary engines

, Compressor shafts

, Crankshafts up to 6 meters long

Industrial Requirements

, Small batch production

, Large and heavy parts

, Many different varieties

Our Solution

, A high degree of flexibility

, Multifunctional machines

, High stability

, Integration of multiple technologies

(turning, milling, drilling)

, Efficient production of prototypes

and small batches

Your Advantages

, Flexible machine concept

, Robust machines

, Different sizes

, Workpiece-related engineering

04 | 05

Cutting to Length and Centering / End Machining

Utilizing rigid workspindles on both sides, the initial processing step quickly

mills the crankshaft to proper overall length. Oversized on purpose, the

machine is fully capable of handling large material stock and parting line

conditions. Subsequent to the facing task, center holes are then bored to

provide the reference and datum points for all subsequent machining

operations. Optionally, the machine can also perform hollow milling of

oil seal and postend diameters to form clamping surfaces for following

operations. Of course, most of these tasks are being done on both

crankshaft ends simultaneously, giving our machine concept a distinctive

production rate advantage. Precise clamping and alignment units ensure

compensation for stock and imbalance conditions.

Machining Options

, Cutting to length and centering

, Mass-centering, if interfaced to a balancing machine

, Hollow-milling of clamping diameters on oil seal and postend diameters

Your Advantage

, Precise pre-machining provides a solid basis for down-stream operations

, Uniform and simple machine concept

, Short cycle times due to simultaneous machining on both part ends

, Time-proven MAG standard machine concept

, Machine design optimized for size and inline layout

, Machine configuration and footprint uniform with oil hole drilling, turning

and roller burnishing machine

Oil Hole Drilling

The two drilling heads operate synchronized but fully independent of

each in B-axis and Y-axis direction to perform oil hole drilling tasks on a

horizontally chucked crankshaft. Each machining head uses its own tool

change rack, enabling the machine to produce virtually every oil hole

configuration at the shortest possible cycle time.

State-of-the-art drill bit technology combined with a proven MQL system

for optimized productivity and extended tool life times. The horizontally

arranged single-part concept allows for utilization of simple and economic

workpiece handling equipment.

Special solution: Both technologies oil hole drilling and roller burnishing

can be combined in one machine.

Your Advantage:

, Fully flexible tool change capability allowing for one unit in operation

at all times

, Simple machining process, conventional drilling instead of deep

hole drilling

, MQL system for optimized production rate and tool life

, Time-proven MAG standard machine concept

, Machine design optimized for size and inline layout

, Machine configuration and footprint uniform with cutting to/centering,

turning and roller burnishing machine

Cutting to length and centering Oil hole drilling

Our Technology Newcomers

04 | 05

Turning low end Roller burnishing of thrust bearing

CNC Turning

Turning is an ideal process for machining of various concentric features,

such as: flange and postend areas, counterweight topping, thrust bearing

faces and reluctor ring diameters or mounting surfaces.

Our special crankshaft turning cells offer the inherent flexibility to be

equipped in accordance with the respective operation sequence, machining

task and associated requirements. The available machine spectrum ranges

from 2-axis to 4-axis configurations to achieve the most cost-effective

solution for the specific application. For boring and milling applications,

including Woodruff keyways and timing notches, the special crankshaft-

turning cells can be equipped with a variety of driven tool options.

Your Advantage

, Simple machine concept with the flexibility of a multi-function

turning center

, Cost-effective machine design

, Time-proven MAG standard machine concept

, Machine design optimized for size and inline layout

, Machine configuration and footprint uniform with cutting to

length/centering, oil hole drilling and roller burnishing machine

Roller Burnishing

Roller burnishing can substitute machining of thrust wall faces by hardening,

grinding and super finishing. The process initiates by measuring the lateral

position of the previously processed thrust wall faces inside the machine,

utilizing a touch trigger probe system. Thereafter, the thrust walls are

precision turned and subsequently roller burnished.

The purpose-made burnishing tool uses controlled pressure applied via

rollers to compress the material on the surface of the thrust wall faces.

The result is a compacted surface with increased hardness and much

smoother finish quality, providing a significant improvement of the bearing

contact area. Our cost-effective integration of the roller burnishing

technology into a standard crankshaft machining cell allows to combine

other finishing tasks, such as turning of the flywheel pilot diameter,

postend and reluctor ring features into a flexible multi-task operation.

Special solution:

Both technologies oil hole drilling and roller burnishing can be combined

in one machine.

Your Advantage

, Cost-effective machining process, highly accurate

, Flexible machine concept with high degree of utilization,

due to the underlying presence of a CNC turning machine

, Time-proven MAG standard machine concept

, Machine design optimized for size and inline layout

, Machine configuration and footprint uniform with cutting

to length/centering, oil hole drilling and turning machine

Bearbeitung des PasslagersÜberdrehen des Zapfens

06 | 07

Turn-Turnbroaching

Turn-turnbroaching is a combination of radial plunge cutting for roughing

and rotary broaching for finish machining. The tool cartridges are arranged

on the outer circumference of the tool disc and engage in material removal

action according to the process sequence. The large quantity of available

cartridges allows for redundant tool capacity and consequently an optimized

tool life strategy.

The broaching heads feature CNC-controlled vertical, horizontal and rotary axis

capability. This allows for utilization of the same cutting tool configuration for

various crankshaft types with different bearing dimensions. Flexibility, high

machining accuracy and short cycle times are the most significant

advantages of the turn-turnbroaching technology.

MAG turn-turnbroaching machines are used for machining of main bearing

and crankpin journals on small size crankshafts. Crankshafts for medium

to large size cars, as well as truck size applications, consist primarily of

machining of concentric features, such as main bearing journals, which is

often expanded to flange and postend areas.

Your Advantage

, High process flexibility

, High machining accuracy

, Short cycle times / high productivity

, Complete machining of all concentric crankshaft features in

a single-setup

, Machine configuration and footprint uniform with high-speed

external milling

Tandem-Disc Turn-Turnbroaching

The twin tandem disc process demonstrates the flexibility and basic rigidity

of the MAG turn-turnbroaching machine more thoroughly than any other

comparison would be able to. Rough machining of four main bearing

journals simultaneously allows for unparalleled production increases.

Want more? Tandem-disc turn-turnbroaching combines the salient

advantages of rotary broaching and turn-turnbroaching for a process that

delivers high productivity and tight tolerances.

Our Technology Classics

Turn-turnbroaching

High-speed external milling

High-Speed External Milling

H-S external milling provides better process flexibility, shorter cycle times

and higher accuracy. The increase in workpiece quality results from low

cutting forces and consequently smaller workpiece deflection, as well as

the ability to produce less machining heat and to discharge of the present

heat far quicker and more efficiently into the metal chips and away from the

tool, workpiece and machine. The MAG H-S external milling process rotates

a concentrically clamped workpiece at low speed. All machined surfaces

are produced by CNC controlled milling heads moving independently, but

fully synchronized to the angular position of the workpiece, i.e. in a „chase-

the-pin“ mode. Most commonly, H-S external milling is used for machining

of crankshaft pin journals, where it offers the convenience of parameter

programmable stroke and index positions.

Other preferred applications include machining of main bearing journals,

counterweight diameters and reluctor ring mounting surfaces on crankshafts,

as well as lobes on medium to large size camshafts. H-S external milling

has the ability to really take advantage of lower material stock conditions, as

more commonly seen today on small car to medium truck size crankshafts.

Your Advantage

, High workpiece quality due to low cutting forces and efficient

discharge of cutting heat

, High process and change-over flexibility

, Simple machine concept with reserves to take advantage of

future tool developments

, Allows for simple workholding arrangements

, Short cycle times / high productivity

, High machine availability due to shorter tool change times,

but longer intervals

, Machine configuration and footprint uniform with turn-turnbroaching

14 | 15

New Process of Hyper Speed Milling

MAG meets the industry demand for efficient production.

In collaboration with a tool manufacturer, we have developed an outstanding

cutting inserts quality which enables our customers to significantly reduce

the processing time required to mill crankshafts.

This is Possible Because

, The design and performance of our machines are the basis for the

extraordinary increase of cutting speeds

, Our milling supports ensure a smooth and safe turn to achieve the

required surface qualities

, Strong drives ensure these high cutting speeds which reduce

processing time

Your Advantages

, Increased efficiency by reduced processing times

, Sustained high quality

, New technology can be integrated within existing series

New Technologies

08 | 09

Motorcycles and Small Full to Large Size Cars Medium to Heavy Duty Trucks

Applications to Medium Size Cars and Light Duty Trucks and Off-Highway Engines

Cutting to length and centering CE series CE series

Turning VDF T series VDF T series VDF T series

Turn-turnbroaching CB series CB series CB series

High-speed external milling CM series CM series CM series

Oil hole drilling CD series CD series

Precision turning and burnishing of thrust walls VDF T series VDF T series

Product LineFields of Application

Our Range of Applications

4-Cylinder Automotive Cast Iron Crankshaft

1. Cutting to length and centering

Machining Task Machine Type

CE series

2. Rough/semi-finishing of flange,

postend and main bearing journals

3. Rough/semi-finishing

of crankpin journals

4. Oil hole drilling

5. Finish machining of thrust walls

CB series

CM series

CD series

VDF T series

10 | 11

6-Cylinder Automotive Steel Crankshaft

1. Cutting to length and centering,

pre-machining postend

3. Semi-finishing of flange, postend

and main bearing journals

4. Semi-finishing of crankpin journals

5. Oil hole drilling

6. Finish machining of thrust walls

2. Rough machining of main

bearing and crankpin journals,

with counterweight topping

Machine Type

CE series

CM series

CB series

CM series

VDF T series

CD series

Machining Task

12 | 13

We offer TurnKey Solutions

1. Inquiry / Concept Phase

We provide you with an initial concept of a recommended manufacturing

process and production line arrangement, all tailored to your specific

crankshaft and requirements. The level of detail work included in the initial

concept already includes process sheets, identification of machine type,

machine count and outline of purchased equipment.

Your Advantage

, Utilization of best-practice approach combined with our crankshaft

machining experience right from the start of the concept design phase

, Selection of key-partners and sub-suppliers based on the specific

program requirements and product design

, Single-point contact for all concerns of the program

, Quick implementation time

2. Engineering/Design Phase

MAG provides advanced planning of the entire manufacturing system. We

furnish the machining know-how for our own delivery content, as well as

for all operations and equipment provided by sub-suppliers.

Selection of the final process concept is done together with you and the

key-partners as part of the simultaneous engineering tasks.

Your Advantage:

, Centralized project planing results in fewer interfaces –

You communicate with only one partner

, Only minimal planning and engineering efforts from your side

, All elements of the manufacturing system are matched and

coordinated by us

, Know-how transfer materializes already during the engineering phase

Clear interface with graphic support

1

1

= MAG machines

3. Preacceptance

Verification of the machine and process capability is done at the

respective manufacturer’s location together with you. This includes machine

setup, verification runs, part inspection and statistical evaluation of results.

Your Advantage

, Capability behavior is inspected and reviewed at the respective

manufacturer’s site already

, Optimizations are performed in cooperation with you

4. Installation and Commissioning

Installation and commissioning supervision is provided by our own personnel

together with staff from the respective machine manufacturers. Generally,

we employ the same people for the preshipment tests, as well as final

machine installation. Project management responsibility lays with us.

Your Advantage

, Shorter installation times, due to utilization of experienced personnel with

prior exposure to the respective machine equipment and applications

, Onsite project management with single-point contact for you

5. Drilling and chamfering all oilholes

4. Turning and burnishing thrust walls, turning mounting face and gearringseat, including main bearing 1

3. Milling pins with undercuts, topping counterweights

2. Turn-turnbroaching mains, pre-turning faces of flange and reluctorring seat

1. Cutting to length and centering, turning outer diameter flange and stub end

5. Final Acceptance

Machine and system capability runs, data collection and evaluation of

results. Final acceptance provides the proof that the process, machines

and entire manufacturing system are capable at the final installation site

in respect to quality and throughput requirements. Upon final acceptance,

ownership of the manufacturing system is transferred to the customer

and his staff.

Your Advantage

, Machine and system capability verification and demonstration at final

installation site under the management of MAG

, Owner-ship transfer of a fully functional and verified manufacturing

system to you and your personnel

6. Ramp-up Support and Training

All the way through the production launch, ramp-up and optimization phase,

MAG’s onsite staff ensures a seamless transition of ownership and

responsibilities. We provide classroom and on-the-job training and enable

the necessary know-how transfer through subsequent production support

services. Upon request, MAG is prepared to provide you with further support

services based on the applicable requirements.

Your Advantage

, Short ramp-up time

, Ongoing know-how transfer

, Onsite troubleshooting resources for quick reaction time during the

production start and subsequent ramp-up phase

14 | 15

Service and Support

Original Spare Parts

, 24/7 Spare Parts Service

, Spare Parts Package

, Central Warehouse

, MAG Fluids

Spindle Service

, Repair / Overhaul

, Loop Programs / Exchange Spindles

The services team at MAG is your single source for maintenance and productivity solutions designed to optimize plant operations. Through

comprehensive support and factory-direct expertise, manufacturers achieve maximum equipment availability and utilization reducing their cost

per piece. By providing a proven and innovative service and support program, our customers maintain the lowest possible total cost of ownership

of capital equipment throughout the machine’s life cycle.

Service

, Service Hotline / 24/7 Support

, Repair Service

, Maintenance

, Machine Certification and Inspection

, Rebuild

, Retrofit

, Used Machines

, Machine Relocation

, Service Contracts

Engineered Services

, Process and Production Optimization

, Complete Care Packages

, Technology Integration

Training

, Operator Training

, Fluid Training

, Maintenance Training

, Interactive Training

, Programming Training

Software

, Machine Data Acquisition

, Machine Diagnosis

, Condition Monitoring

, Energy Management

, Virtual Machine

MAG IAS GmbH

Location Göppingen

Stuttgarter Straße 50

73033 Göppingen

Germany

tel +49 71 61 201-0

fax +49 71 61 201-353

w w w. m a g - i a s . c o mThe machines shown are examples. Actual machines may vary based on selected options.T7002(01DE)en/500/09.12

Solutions & Applications, Turning

, Milling

, Hobbing

, Grinding

, Honing

, Composites

, Systems Integration

, Automation & Software

, Services

, Tooling & Fluids

, Core Components

MAG is a leading machine tool and systems company serving the durable

goods industry worldwide with complete manufacturing solutions for metal

cutting and composites applications. With a strong foundation based upon

renowned brands such as Boehringer, Cincinnati, Cross Hüller, Ex-Cell-O,

Fadal, Giddings & Lewis, Hessapp, Honsberg, Hüller Hille and Witzig & Frank,

MAG is recognized as the preeminent provider of tailored production solutions

based on state-of-the-art technology. Key industrial markets served include

aerospace, automotive and truck, heavy equipment, oil and gas, rail, solar energy,

wind turbine production and general machining.

With manufacturing and support operations strategically located worldwide,

MAG offers comprehensive lines of equipment and technologies including

turning, milling, hobbing, grinding, honing, systems integration, composites

processing, maintenance, automation and software, tooling and fluids, and

core components.