KRAUSE & MAUSER PRECISION IN FOCUS We split the micron

Transcription

1 Ultra-Precision, High Output, Maximal Productivity Part and Process Technology from KRAUSE & MAUSER Walter Dobesch, Krause & Mauser VDW-Symposium Vietnam 2016 KRAUSE & MAUSER

2 AGENDA The KRAUSE & MAUSER Group Products Processes and technologies

3 The KRAUSE & MAUSER Group KRAUSE & MAUSER Vorsprung durch Freude an der Technik

4 STRUCTURE OF THE KRAUSE & MAUSER GROUP KRAUSE & MAUSER Holding GmbH Oberndorf, Germany KRAUSECO Werkzeugmaschinenbau GmbH MAUSER Werke Oberndorf Maschinenbau GmbH Vienna, Austria Oberndorf, Germany FEIBA Engineering & Plants GmbH TIANI Automationstechnik GmbH Traun, Austria Oberndorf, Germany KRAUSE & MAUSER US Inc. KRAUSE & MAUSER CHINA Co., Ltd. Rockford, IL, USA Shanghai, China MACHINE TOOLS AUTOMATION SERVICES

5 HISTORY OF THE KRAUSE & MAUSER GROUP Ernst Krause founds a company for the manufacture of high precision machine tools in Vienna. The production program of this initial period includes lathes, milling and material testing machines. The company begins the manufacture of three wheel vans The royal armaments factory in Oberndorf is founded. A new type of action is developed for breech loading rifles. The company expands its production to include measuring devices, industrial sewing machines, automobiles, adding and lettering machines. The company achieves a leading position in the fine boring market. The first fine boring machine is launched into the European market The production of calculating machines commences. The production range is further enlarged to include special machines and transfer lines. The company specializes in custom made finish machining solutions with a focus on cylinder heads and blocks Coordinate measuring machines are integrated into the product range. A new assembly facility is built for transfer machines Development of machining centers. The first NC boring heads are developed. Entry into the field of complete machining The first fully automatic assembly lines are produced. Development and reference installation of large, fully flexible machining systems.

6 HISTORY OF THE KRAUSE & MAUSER GROUP 1994 The KRAUSE and MAUSER companies are merged Innovative cracking technologies for machining connecting rods Reference installations for dry machining systems, as well as flexible machining centers using standard modules and flexible transfer lines Foundation of KRAUSE & MAUSER US Inc Take over of TIANI Automationstechnik GmbH, a qualified manufacturer of loading equipment and linkage systems Integration of feiba engineering & plants GmbH in the KRAUSE & MAUSER machine tool group a qualified manufacturer of welding Machines for car body and chassis parts. New generation of PS machining centers out of the modular construction kit Foundation of KRAUSE & MAUSER International Trading Shanghai Co. Ltd., P.R. China PS Invers³: Symbiosis of a Machining Center and a Special Purpose Machine Integration of honing and laser structuring Integration of ball burnishing technology Rapid and sustainable laser applications due to developement of fibre laser Today, while retaining the core competences at its locations, e.g. finish machining in Vienna, the KRAUSE & MAUSER Group has an expanded, modular-standardized technology potential, a global distribution and services network and high potential for the realization of major projects by means of a concentration of capacities. Company Profile

7 PART KNOW HOW THE COMPLETE TECHNOLOGY FOR THE ENTIRE POWERTRAIN Chassis - Front Axle Engine Steering knuckle Drag bearing Steering arm, Tie rod Brake calliper Brake manifold Cylinder head Cylinder block, Conrod Camshaft, Crankshaft, Flywheel, Oil pan Chassis and Rear Axle Transmission Engine Accessories Rear axle housing Axle bridge Differential case Suspension arm Rear axle Trailing arm Transmission case Transmission case cover Selector fork Output shaft Clutch housing Intake and exhaust manifold Water pump housing, Oil pump housing, Fuel injection pump housing Assembly mounting bracket

8 Products KRAUSE & MAUSER

9 PRODUCTS Transfer Lines Special Purpose Machines Crack and Assembly Systems PS-Series Machining Center PS INVERS³ Hybrid Machining Center Turn-Key Solutions PRÄZOPLAN Ultra Precision and Highly Productive Machining Center PS ReFlex Fully Flexible Rotary Transfer Machine

10 CRACKING AND ASSEMBLY SYSTEMS 45 Years, 350 Conrod projects worldwide! Conrod cracking and assembly system

11 HYBRID MODULES PS INVERS³ PS INVERS³ - the combined advantages of a machining center and a special purpose machine Flexibility and Modularity M/C New Kinematics Multi-Spindle M/C INVERS³ Productivity Work piece Quality TFM/SPM Spindles

12 HYBRID MODULES PS INVERS³ PS INVERS³ - the combined advantages of a machining center and a special purpose machine PS INVERS³ machining: no tool change times no tool change faults extremely short chip- to- chip times future- proof module investments suitable for wet and dry machining operations (free chip fall) multi- spindle heads can be mounted on up to four sides = flexibility³ machining designs with optimized power flow allow high cutting output at highest machining precision different operations can be combined in one set- up (no faults due to re- clamping) short time from one multi- spindle machining operation to the next (cycle is shorter than on a transfer line!) change- over flexibility

13 PS ReFlex The flexible investment and future proof machining concept for 5-axis machining of complex work pieces. Krause&Mauser has developed an new machining philosophie with the PS ReFlex Full Flexibility Single spindle 5-axis machining (3-axis on the tool / machining unit, 2-axis on the work piece) system errors can be corrected separately Rotative work piece transfer

14 Machine Centers PS/MC a success Story Customer Satisfaction by Continous Innovation 1960ies Revoltionary Concept 1980ies Flexible Machining FFS w/ Central Control 1990ies Innovativ Axis Configuration Full Flexibility and Compatibility Open Interfaces instead of complex Machining Modules Future Customer Requriements considered by Clever Machine Configuration 2000s Flexibility by Modular Machines High-Power Cutting KRAUSE & MAUSER 2014

15 PRÄZOPLAN Overcoming the limits; The split µ with multiple output PRÄZOPLAN Overcoming the limits The split µ with multiple output The most important criteria of effectivity in parts construction are: QUALITY <> PRECISION AND SURFACE QUALITY PRODUCTIVITY <> SHORT PRODUCTIVE AND NON- PRODUCTIVE TIMES In which, on the part of the machine tool: QUALITY can only be optimized by high rigidity and precision of the guiding system PRODUCTIVE TIME can only be optimized by high rigidity allowing high metal removal rates NON- PRODUCTIVE TIME can only be optimized by high dynamics in speed and acceleration

16 PRÄZOPLAN Overcoming the limits; The split µ with multiple output For the machine tool, the requirements of: DYNAMICS <> LOWEST POSSIBLE MASSES RIGIDITY <> HIGHEST POSSIBLE MASSES are fundamentally opposed to each other. None of the machine concepts available on the market have so far been able to meet the above mentioned requirements simultaneously in optimized fashion. For the first time in the world, PRÄZOPLAN combines these requirements simultaneously by means of the fundamentally new concept of the aerostatically planar guide, in which a single slide generates the travel directions X and Y simultaneously by sliding over a plane instead of the usual stack of linear guides. It overcomes the physical limits as follows: PRECISION: no adding up of the errors of two stacked linear axes, µ accuracy through extremely high levelness of the guiding plane RIGIDITY: very short force flow from the carriage directly into the machine base, high- rigidity aerostatics DYNAMICS: very compact slides, drive directly in the center of mass, thus no vibration excitation 1 guide for 2 directions - the PRÄZOPLAN-principle

17 Processes and Technologies KRAUSE & MAUSER

18 LASER CRACKING Faster safer cost saving Connecting Rod / Cracking Technology Development of cracking technology with 40% cost reduction USP - Laser notching for: high strength / ductile and surface hardened materials - Profiled laser notching - Low energy fiber laser - Innovative machine concepts for high product and production rate flexibility Market leader with more than 50% market share within 5 years! Laser notching: Mauser-Patent No. DE No. DE Assures best tool life time and accuracies Laser notching of a truck crankshaft bearing cap Laser notched crankshaft bearings Cracking of a crankshaft bearing cap Crankshaft bearings without bearing caps Laser head Cracking mandrel

19 LASER CRACKING Faster safer cost saving Applications in the automotive industry: Axle housing Bed plate and differential carrier bearing cap Brake disk Differential case Car, truck & large engine connecting rods Cylinder block bearing cap Cylinder block Cylinder head

20 LASER STRUCTURING Lower investment cost higher process stability Advantages of laser adhesion structures: Slipping of the crankshaft bearing shell in high- dynamic engines is eliminated, and thus higher torques can be transmitted Elimination of the oil residue and bearing damage Investment cost reduced by approx. 50 % as compared to honing operations Maintenance and operating cost is reduced in comparison to machining with lubrication No restriction for gauging operations and classifications Minimum floor space requirements Process flexibility is possible

21 FORM BORING - TRUMPET Better lubrication less strain One method of form boring is a trumpet shaped contour of the connecting rod pin bore. The tolerance band for producing this trumpet bore contour ranges from 3 to 5 µm. Advantages of the trumpet shaped contour: Prevention of possible damage to the piston pin Reduction of the piston pin load Improvement of the piston pin lubrication Trumpet contour within +/- 4 µm tolerance

22 FORM BORING OVAL BORE Better lubrication less strain Function of oval shape: STEP 1: Pin bore is compressed and deformed by piston pin after ignition at top dead center Without oval shape: Piston pin touches pin bore on wide area and causes flattening of the piston pin, high friction and strain With oval shape: Piston pin touches pin bore on small spot only, avoiding flattening of the piston pin and reducing friction and strain Compression Force Without oval shape With oval shape Pin Bore Piston Pin showing internal stress caused by compression force flattening the piston pin

23 FORM BORING OVAL BORE Better lubrication less strain Function of oval shape: STEP 2: Pin bore releases to initial shape after bottom dead center Without oval shape: Piston pin and pin bore release to initial shape With oval shape: Piston pin and pin bore release to initial shape while sucking oil into chambers on each side of the piston pin Chambers depending on clearance fit between pin bore and piston pin Without oval shape With oval shape Pin Bore Piston Pin showing stress relief returning from flattened to initial round shape

24 BALL BURNISHING Lower cost shorter process highest quality Burnishing technology Cancellation of pin bore bush to reduce heavy metal content in engine BURNISHING BALL R FEED DIRECTION SURFACE

25 BALL BURNISHING Lower cost shorter process highest quality Burnishing technology Perfect surface quality with increase of percentage contact area Hardening of surface Surface super-finishing for hard materials Burnishing Fine boring

26 BALL BURNISHING Lower cost shorter process highest quality Burnishing technology Burnishing tooling with media loaded burnishing balls Usage of emulsion or air pressure Long tool life BALL

27 FINE MACHINING Highest precision for highest performance requirements Due to strict exhaust emission standards it is important to machine perfectly adjacent chamfers or radii of the actual valve seat. The valve seat machining operation is performed by a rotating tool, numerically controlled via Z- axis and a U1- axis with an operating range of 10 mm/radius. The valve guide diameter is reamed with a guided reamer tool to line up with the bore, using the U2- axis. Advantages of the NC-controlled valve seat machining process: All forms of chamfers (also convex and concave), radii, and curves can be machined Only one special tool is needed for the intake and exhaust valve seats Balanced out at each position Valve seat angle 20 minutes Valve seat runout 10 µm Valve seat roundness 5 µm NC-controlled valve seat machining: KRAUSE & MAUSER test machine with a spindle mounted valve seat NC boring head and a cylinder head mounted on the cube type fixture

28 FINE MACHINING Highest precision for highest performance requirements Today, cylinder boring with a slip- on honing attachment is considered to be almost standard. However, this results in an overhang increased by approx. 50 mm. KRAUSE & MAUSER has developed a new elastic system suitable for size control and wear compensation that eliminates an increased overhang. Advantages of the new system: An eccentric spindle is not required, therefore the maximum spindle bearing diameter can be used The machining process uses a slip- on honing jig The maximum overhang ratio from spindle bearing to cutting tool is 3:1 Highest rigidity due to a well braced, elastic system Outfeeding/flex- up stroke 0.5 mm/radius Size controlled semi finish and reverse finish boring Roundness 6 µm Barrel form 8 µm Cylinder boring: KRAUSE & MAUSER test machine with a spindle- mounted boring head and a cylinder block mounted on a cube type fixture

29 REFERENCES

30 Thank you! Walter Dobesch Sales International Krause & Mauser Krauseco Werkzeugmaschinen GmbH Wolfganggasse A-1120 Wien D-Tel: A-Tel: Mob: Dobesch.W@krause-mauser.com Philip Nowack Executive Proposal Manager Krause & Mauser Krauseco Werkzeugmaschinen GmbH Wolfganggasse A-1120 Wien D-Tel: A-Tel: Mob: Nowack.P@krause-mauser.com KRAUSE & MAUSER