Crankshaft/camshaft production systems RFK/DRZ/MCC 15/RFN

• tool generates the cutting speed
• workpiece generates the feed rate
• use of internal cutters
• the workpiece is surrounded by the tool, i.e. the inner tool diameter exceeds the maximum workpiece swing diameter and the clamping chuck diameter
• tool profile is designed according to the profile to be milled
• for the machining of crankpins, 2 interpolating NC axes are used which are positioned eccentrically to the workpiece centre and/or the concentric main bearings of crankshafts
• rotary feed is generated by the workpiece rotary axis, whilst the milling unit(s) is/are following as required using one/two linear axis/axes
• the plunge cut to the journal diameter is either carried out using the linear axis of the milling unit whilst the rotary axis is stationary or using a spiral motion with interpolation of the two axes. During the plunge cut, the cheek faces can be completely or partially machined

• in order to withstand cutting forces, workpieces are clamped and supported by two hydraulic clamping chucks with electrically synchronized rotation and by an additional steady rest which can be positioned using NC programming
• steady rest travels on the guideway below the milling slides and is positioned between the two milling units on twin-spindle machines
• machining using one or two milling units is possible
• machining of bearing diameters and undercuts in a single operation is feasible
• simultaneous machining of main bearing and crankpin journal profiles is possible
• use of gang cutters is possible
• high precision of machined surfaces makes rough grinding obsolete

The following features can be machined (also in combination):
main bearings, crankpin journals, main bearings and crankpin journals in one set-up, cheek faces and cheek outer diameters, undercuts, cheek profiles

• workpiece generates the cutting speed
• tool generates the feed rate
• plunge turning using standard inserts in combination with a chasing operation, specifically developed for this purpose and patented by HELLER, enables cost-effective and highly precise machining of any diameters and surfaces positioned concentric to the rotary axis
• extended tool operation times due to the use of duplicate cutting edges
• fast cutting edge change results in extremely short chip-to-chip-times
• automatic cutting edge measurement in two directions
• all concentric diameters (main bearings, undercuts, grooves, flange and stub end) can be machined in a single set-up
• robust machine design also allows heavy-duty cheek face cutting or cutting of the cheek outer diameter

• workpieces are clamped using two hydraulic, electronically synchronised clamping chucks; retractable clamping jaws are available as an option
• in order to withstand cutting forces, workpieces can be supported with an additional, steady rest positioned using NC programming
• steady rest travels on a separate guideway to ensure unrestricted positioning within the travel path
• machining using either one or two turn-chasing units is possible
• high precision of machined surfaces makes rough grinding obsolete

The following features can be machined (also in combination):
main bearings, undercuts and grooves, thrust bearings, flange diameters, stub-end diameters, concentric profiles, crankpin journals by means of eccentric clamping (special version), cheek faces and cheek outer diameters, chamfering (also eccentric and circumferential)

• a proven and tested HELLER machining centre for heavy-duty cutting provides the basic machine with the corresponding serial components
• machining unit can be traversed via the NC axes in transverse (X-axis) and vertical (Y-axis) direction
• traversing in longitudinal direction (Z-axis) is accomplished using two synchronously driven ball screw drives, providing the NC rotary table motion
• workpiece rotation into the required machining positions is accomplished as follows: for type ‘C’ and ‘E’ by means of the NC rotary table (B-axis) and for type ‘D’ by means of the NC rotary axis (A-axis) and the NC rotary table (B-axis)
• correction of all workpiece features to be generated is possible via user-friendly input screens at the HMI
• large operator doors and vision panels provide excellent visibility of the work area
• swivel operation of the fixture makes manual loading of the machine easy
• outstanding accessibility for all maintenance and repair tasks

• loading and unloading of up to three workpieces parallel to machining
• use of multi-spindle heads is possible
• machine can be designed for MQL (minimal quantity lubrication) or coolant lubrication

The following features can be machined (also in combination):

MCC 15-C (Centring): cutting to length, centring of flange and stub end, turning of flange and pin diameter, circular milling, milling of orientation surface(s)

MCC 15-D (Drilling): pilot holes, cross holes, diagonal holes, chamfering of the hole exits, weight reducing holes

MCC 15-E (End machining): needle bearing hole, flange bores, dowel hole, bores at the sprocket seat, bores at the stub end

• tool generates the cutting speed
• workpiece generates the feed rate
• use of external cutters
• cutter diameter can also be used for most hollow cam profiles.
• tool profile is designed according to the profile to be milled
• 2 interpolating NC axes are used for the machining of cam profiles
• rotary feed is generated by the workpiece rotary axis, whilst the milling unit(s) is/are following as required using one/two linear axis/axes
• the plunge cut to the cam profile is either carried out using the linear axis of the milling unit whilst the rotary axis is stationary or using a spiral motion with interpolation of the two axes
• in order to withstand cutting forces, workpieces are clamped and supported by two hydraulic clamping chucks with electrically synchronized rotation and by one or two additional steady rests which can be positioned using NC programming

• steady rests travel on a separate guideway below the milling slides to ensure unrestricted positioning within the travel path
• machining using one or two milling units is possible
• machining of cam profiles and chamfers in one operation is feasible
• use of gang cutters is possible
• radial alignment by means of bore or groove is possible
• high precision of machined contours makes rough grinding obsolete

The following features can be machined (also in combination): cam profiles made of cast and forged camshafts, cam profiles made of bar stock, cam profiles with circumferential chamfers/profiles, cam interspaces (special application)