Efficient machining of

Crankshafts and Camshafts

 Contents

2 Crankshafts

2 Turning of crankshafts

2 Flange - Stub end

3 Wiper inserts

3 Thrust Bearings

4 Main Bearings

5 Turning or Turn- Broaching

6 Inserts and grades

7 Milling of crankshafts

7 Internal Milling of crankshafts

8 External Milling of crankshafts

10 A new approach for a better crankshaft quality

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.

The demands on crankshaft material, therefore, are in-

creasing, while the crankshafts themselves become smaller.
The many different designs of crankshaft vary consider-
ably, and even during mass production there can be subtle
differences from one to another.

To machine such a variety of cranks, Sandvik Coromant

has developed tool systems which are based on well de-
signed and production tested components and inserts.

Four cylinder crankshaft - Flange, Stub end and Main bearings

are machined

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.

These operations are performed on normal Turning

Lathes, or increasingly on special Turning- or Turn-Turn
broaching centres, used to machine the ends of the crank-
shaft as well as the areas around the main bearing centre
line.

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.

As the crankshaft is still unbalanced at this stage, the max-

imum RPM is limited and so is the cutting speed. That
makes the feed rate even more crucial. The use of Sandvik
Wiper inserts guarantees good surface finish even at high
feed per revolution. Next to machining time costs could,
for example, be saved by using all 8 cutting edges on a
CNMU-Type insert. Wherever possible, we try to use the
strong 100 degree corner, especially in cases of interrupted
cuts or more heavy chiploads.

Wiper inserts
Wiper inserts are innovative high-produc- Standard corner radius

tivity inserts for turning. Due to a subtle

change to the insert corner-radius the
feed rates can be doubled without chang-
ing the surface finish.
Wiper radius
If the feed can be doubled, the cutting
time is halved and almost twice as many
components are made in the same time.

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.

Using a feed of fn 0,12 mm, a surface fin-

ish value smaller than Ra<0,4 m can be
achieved - the optimum starting point for
the roller burnishing operation which fol-
lows.

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.

The small disks allow a collision free operation between

the crankshaft cheeks, giving a short overhang and maxi-
mum stability for the mounted cassettes.
The Sandvik Coromant disks and cassettes are designed in
such a way that an individual assembly of all tool posi-
tions is possible, allowing a short indexing distance during
the operation, ensuring minimum downtime from an opti-
mized cutting sequence.

The 45 cassettes per disk allow an efficient number of sis-

ter tools to be mounted, so that, depending on the indi-
vidual contact time of each cutting edge, the most eco-
nomical arrangement of inserts can be selected.
Sandvik cassettes are very stable, simple to exchange and
easy to clean.

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 .

Alternatively, multi-cutting edge inserts with 3 or more

teeth are used when the final bearing diameter is produced
using a simple turning operation. The disadvantage of the
Turn- Broaching method - the very long chips sometimes
produced on steel crankshafts - is avoided by this turning
method. Better surface finish and a longer tool life how-
ever, are additional advantages of this turning technique.

Turn Broaching

Turning thrust bearings

In cases where the thrust bearing to be machined requires
axial undercuts adjacent to radial undercuts, there is no al-
ternative but to use the turning operation.

Sandvik applies standard inserts wherever possible, so we

can select between multiple grades and geometries in order
to get the best tool life and surface finish.
The insert layout for the different cassettes is designed to
optimise the indexing of each insert, and hence make the
best use of all cutting edges and reduce the carbide cost
per crankshaft to a minimum.

As part of the Sandvik service package we give support to

the MTMs as well as to the end-users. We calculate cutting
data, operation plans and assembly lists. We train
customers machine operators with regard to tool-related
items, and our specially trained engineers help coach
crankshaft production engineers world wide.

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

341006 152N2 Z 465

341.G.530-294 Z 465
341.G.530-369 Z 465

Please inquire for

341.G.DCHT-005 further grades and 4125
341009150N1 dimensions. 4125

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.

Forged steel crankshaft blanks for

truck engines, for example, require
tools which can withstand heavy
chip loads over a long period of
time. The need for adequate chip
pockets, and the restricted internal
diameter, limits the number of ef-
fective inserts. By positioning
these inserts, with 4 or 8 cutting
edges, tangentially or laterally, a
maximum edge security is
achieved. The inserts are
mounted in replaceable seg-
ments, which are specially hard-
ened to give maximum tool life
to the body and allow machin-
ing to close tolerances over a
long period.

The simple cutter body construc-

tion and the stable segment system
in combination with the Sandvik
tailor made inserts contribute to a
very reliable and economical tool
system.
Segment for
split pin
crankshaft

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 technique of external milling has seen its ups and

downs during this long period, but has always been suc-
cessfully applied. Developments in machine tooling in re-
cent years, however, have brought about a renaissance of
external crankshaft milling. In particular, the universal
possibilities allowed by modern NC controlled machines,
combined with improved cutting tool materials and high
precision milling cutters, have allowed the development of
new and far more economic production methods.
External crankshaft milling, with two cutters on one ma-
chine, allows both the simultaneous machining of pins and
main bearings, and also the milling of cheeks, flanges or
timer ring seats in one set up.

The crankshaft rotates slowly around the main bearings

centerline and so creates the circular cutting feed over the
respective radius, while the required cutting speed is pro-
duced by the rotation of the milling cutter. To machine
the pins, the milling cutter follows the eccentric move-
ment of the pin, while milling its diameter in a linear mo-
tion.

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.

In most cases the cutter width corresponds to the bearing

width, and the cutter diameter has to be large enough to
mill the pin in the lower position without colliding with
other parts of the crankshaft or the clamping chuck. The
most common cutter diameter is 700mm.

Sandvik produces such cutters equipped with exchange-

able segments, which are easy to change in case repair is
needed. The close insert pitch gives a smooth cut, good
surface finish and low chip load, which again results in
close tolerances on the crankshaft. Sandvik has supplied Roughing
cutters equipped with up to 270 inserts. profile

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.

External crankshaft milling allows for high quality surface

finish with close profile and position tolerance to be ob-
tained. Green grinding of bearing diameters is not neces-
sary and roller burnishing of the undercuts can be done
directly after the milling operation.

Extremely short machining times, high product quality

and a very secure production process make the external
milling method both an interesting and economical form
of machining technology.

Finishing
profile

9
A new approach for better
crankshaft quality

Engine builders demands' for better surface quality, lower

friction and improved fuel efficiency are sometimes con-
trary to the needs for reducing part and production costs.

A big push forward to fulfil those wishes brought a com-

pletely new approach to external crankshaft milling by
Sandvik Coromant. Considerable quality improvements
as well as a drastic reduction in production costs were the
result.

Up to now, the milling operations have usually been split

into a roughing and finishing. The premilled profile, pro-
duced by the roughing cutter, left some material for the
finishing operation on the bearing diameter as well as on
the oil collar faces. The finishing cutter, working like the
roughing cutter as full side and face mill, had to take away
the rest of the material.

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.

As a result, the topographical condition of the finished

surfaces are influenced by all those factors and very often,
because of their reduced tolerances, often not good
enough to pass statistical quality control. And, as we
know, in engines with crankshaft guided connecting rods,
the surface quality of the oil collar faces are extremely im-
portant.

Sandvik Coromant investigated the machining process, the

crankshaft behaviour during machining action and also the
cutting forces working on both the crankshaft and milling
cutter.

10
 Insert layout and cutting sequence

Conventional version
Adjustable Fixed pocket
insert design design

Insert and cutter design

The findings lead to a new insert and cutter design but
more important to a new cutting sequence.
With this new arrangement, the roughing cutter semi-
finish mills the bearing diameter before being finish
ground in a later operation.

That leaves just the finishing cutter to work on the oil

collar faces and the undercuts.
We tested these new developments on a pin milling
operation on a 4 cylinder steel crankshaft under real-

New version
time, two shift production conditions. This application
has now been repeated constantly for the past year.

The improvements we achieved in this operation re-

garding component quality and carbide cost reduction
were enormous.

Tool life for the roughing cutter went up to

4000 crankshafts = 16 000 pins
Tool life for the finishing cutter went up to
8000 crankshafts = 32 000 pins
Improvement of surface quality on oil collar faces
= 280 %
Reduction in carbide cost per crankshaft
= 57 %

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.

Sandvik, therefore, have developed some high perfor-

mance milling cutter variations, which show a new ap-
proach to camshaft milling. This programme contains tan-
dem cutters for the simultaneous milling of two cams as
well as cutters for milling the cam length, including the
undercuts.

All cutters can be delivered in solid versions or equipped

with segments. Cast iron camshafts with their small
amount of stock can be milled with cutters having extra
close pitch. That could mean, for example, 70 effective
cutting edges on a 500 mm cutter, giving a smooth cut,
low cutting force variation and a long tool life. Inserts
with well tuned grades, optimised geometries and up to 8
cutting edges result in safe production and low production
cost.

Camshaft for a truck engine - milled from a solid bar

12
Milling Cutter Profiles

Cam Profiles

One of the new Sandvik developments, the combined

profile and chamfering insert, allows a drastic increase of
effective cutting edges in a given cutter diameter. It also
offers easy access for insert changing, especially important
when tandem cutters are used.

Sandvik takes particular care that our cutters are produced

with an exact run out and a good overlapping of the indi-
vidual insert rows in order to get perfect cam surfaces and
profiles.

Milling insert with

2 left and 2 right
hand cutting edges

Cast Iron camshaft for a 4 cylinder 16 valve engine

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:

Reliable and secure in production,

easy to handle and as few different
parts as possible. These are just
some basic wishes.

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.

The cutters shown have a diameter of 500 mm and are

configured in the latest modular design. The segments,
which carry the inserts, are separated from the cutter
body.

They are identical and can be mounted in all positions.

So a customer, having different cam profiles to machine in
low batches, can keep the cutter bodies and exchange only
the individual segments.
This is another point to consider for reducing the capital Cutter
tied up. profile

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

All segments are produced with extremely close tolerances

and placed precisely against a shoulder and radially on the
circular ground diameter of the cutter body.

The cutting force is transferred by a simple "key and slot"

system and the segment position is securely fixed by two
strong screws.

Cutting edge, component and the regular repeating impact

force acting on the camshaft, can lead to vibrations.

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.

The intensive discussions we have with our customers and

machine tool builders before we start a project, are always
a guarantee to get the expected performance and best re- Milling of 6 cylinder steel camshaft
sults.

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

Printed on recycleable paper

C-2940:091 ENG/09 Printed in Sweden
AB Sandvik Coromant 2003.09 Your Productivity Partner Sandvikens Tryckeri