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COMPETENBURKHARDT+WEBER PROJECT-REPORTCE SPRING 2014 High-Tech Engine Block Machining New Motor Designs – New Production Plant – New Process Technology Inserting of 2 cams­ haft and 1 crankshaft boring bars With the investment in a complete The task was to find a flexible and ex­ nology and productivity requires manu­ new engine manufacturing plant, a pandable, modular solution for the com­ facturing engineering creativity in every major diesel motor manufacturer in plete range of V12, V16 and V18 motors. aspect. And with the production quantity China is breaking new ground, virtual- Besides the technical factors also the forecast, and the product mix at hand, ly on green pastures, to expand their commercial tasks were challenging. The a substantial machine tool investment production capacity significantly. The goal was a highly economical solution, needs to be contracted and engineered. driving factor is to offer new, modern already profitable in the production start­ V-type engines, for the fast growing up phase, and gradually expandable to The historically proven and still up to Chinese market, and the overall chal- the highest production quantities, while date manufacturing philosophy using lenging world market. maintaining productivity, using a “cookie custom, limited purpose machines ad­ cutter” type principle. equate for each process step was not Led by modern engine concepts, the to be considered. An example of such experts of the motor manufacturer For the planned capacities, initially 200 a system would be the use of portal searched thoroughly for a leading suppli­ motors have to leave the factory in the milling machines for cutting all engine er for a modern block machining pro­ first year, increasing over the following case sides together with producing the cess, best suited for the initial and final years to 3,000 units per final production cylinder bores, plus a custom deep­hole production quantities, with a seamless forecast for the V12 and V16 engines. In drilling machine for the oil bores and a growth potential for higher demands. addition, subject to market demand, a special machine for crankshaft and After comparing all known globally recog­ large V18 diesel engine case is added. cam shaft boring. Already with the initial nizable suppliers, BURKHARDT+WEBER Every enthusiastic manufacturing engi­ investment, such a concept would re­ manufacturing systems was chosen as neer will certainly agree that such a proj­ quire for the start­up phase, all special system solutions provider for the engine ect is “a dream comes true” opportunity. machines built for the final production block machining process. The development of such a completely volume requirements. In general this cre­ new production plant, leading in tech­ ates a bad redundancy for several years, 2 BW COMPETENCE with a significant excess capacity during Most often supplied for large diesel en­ a gradual ramping up production. The ini­ gine machining tasks is the MCX 1200 as Tool Magazine tial poor efficiency, with lack of back­up a core machine, together with a “cookie machines and little time for maintenance cutter” type multiplication technology and repair tasks, and the excessive high from BURKHARDT+WEBER it provides ­ Total magazine capacity 570 tools capital investment volume, would have for a risk­free redistribution of good and condemned itself as a failure, right from practical clamping technology and fully ­ Designed for 300 tools up to the beginning for such a far reaching tested spindle tools, easy to duplicate for Ø 125 mm, 7 tools up to Ø 225 mm challenge. the future growth stages. This concept 15 tools up to Ø 350 mm and supports all machining tasks and that 15 special angle and milling heads right from the production start, while it “Wunderbar” modular – highly features a low initial capital investment ­ Max. tool length = 1,200 mm for specialized, flexible, and openminded amount for chip cutting machines. deep­hole drilling of oil bores The MCX 1200 has many advantages Strategic business decisions and planning over comparable machines from other ­ Angle heads weighing up to 75 kg for long term success is required in the suppliers. Besides a much larger work with a max. tilting moment of present, deciding for solutions sustainable area overall with long axis travels, the 150 Nm in the long run. So the key issues of this BW series of machines is also equipped project were discussed already at an with a BW designed and built unique early stage with the customer and result­ rotary table unit. This features an ex­ Pallet Changer ed to a technically and economically fully tremely high radial and tilting torque, the viable, future­oriented, and flexible, step most important feature to rigidly sup­ Pallet size 1,400 x 1,600 B1 by step implementable complete solu­ port the motor block machining when tion. With BURKHARDT+WEBER such a clamped on its end faces. Thus, even ­ Double pallet changer complete concept always includes the the machining of large V­engines is com­ overall process engineering, the machin­ pleted in only a few machining orienta­ ­ Hydraulic connection at clamping ing process, the tool engineering, the tions. The high torque table benefits are fixture with p>60 bar cor responding work holding technology, resulting from the use of oversized and the supply of process­specific machines, overdimensioned bearing arrangements ­ Hydraulic connection at set­up and last but not least, the CNC part pro­ together with a wide spacing of the axis stations and machine table gramming and run­off with proof of cycle guides. time and quality. Assembly of fixture cover with integra­ ted camshaft boring guides In order to deliver an effective cutting performance at the engine case, the BW machining unit features a 4­stage gearbox supplied with power by a 60 kW spindle motor, which delivers a peak performance of up to 80 kW with an up to 3,500 Nm full duty torque rating. Lead­ ing in head technology the BW machine features a rigid hydraulic 4­point head clamping technology for heavy­duty cut­ ting heads. With a spindle speed range up to 6,000 rpm the MCX 1200 is also best for the machining of cast iron ma­ terials, and has also power reserves for future cutting technology improvements. In order to rigidly power and precisely locate the up to 70 kg weighting tools and especially important for the needed long reaching drilling and facing tools for cam­ and the crankshaft bores, the HSK 100 A tool taper is improved with the BW Ø160 mm face support. A special fluid connection for the demanded high volume coolant supply supporting an economical deep hole drilling operation allows cutting fluid pressures of up to 20 bar with effective flow volumes to 54 gpm and complements the BW spindle technology perfectly. BW COMPETENCE 3 For this project, about 15 customized, are adjusted to bore within a straightness The first BURKHARDT+WEBER task specific milling heads covering all of 5 micrometer. For machining, the tools Machine, a good decision. engine types were designed by BW. are inserted into the part with a fully Stored in the machines’ standard tool auto matic sequence using unique BW At the conclusion of the final acceptance, magazine they are fully automatically tool stations, located at end of the X­axis the Chinese engine manufacturer empha­ ex changed and used as needed. Master­ table travel. sized during the review meeting his overall pieces in engineering are the highly satisfaction with the project and the ma­ challenging work holding fixtures. The Another challenge for the engineers of chining results overall, and reaffirmed his customer quickly recognized the out­ BURKHARDT+WEBER was leading to a pre vious decision for BURKHARDT+WEBER, standing engineering knowledge of the premiere result. The access and the as a premium ven dor for such a promising BW expert team and decided to con­ arrangement of the camshaft bore did and deman ding project, giving us a best part­ tract this task with BW, especially be­ not allow the conventional inserting of ner rating. cause BW maintains its own in­house the support bearings for the line boring fixture design and manufacturing group. tools from the bottom up. Thus a differ­ The overall benefits when compared to Three basic engine block types need to ent practical concept with highest pro­ the commonly accepted portal machine be accommodated with the same fix­ duction safety had to be engineered. A concepts: tures while a minimum number of work special, top loading and extremely rigid, orientations for a complete machining is top fixture was the engineering result. ­ Significantly lower initial investment costs demanded. The final solution results to 8 Supported by a special extra strong en­ ­ About 40% less floor space requirement part location with only 6 hydraulic acti­ gine head housing the support bearing ­ More compact foundation as major vated clamping fixtures.Two of these is assembled to the part after clamping installation time and installation cost fixtures are for vertical engine block it in the base fixture on the machine pal­ reduction orientations and provide an outstanding let. Locked into position by a zero­point ­ Much shorter machine idle times for the accessibility to many part features on all clamping system, this precision fixture tool, head, and pallet changes engine sides via a fast table orientation. supports an ultra­precise concentricity of ­ Optimal chip removal and less thermal This includes the generation of cylinder all bores machined. implications banks and cylinder bores. A highlight of ­ Highest line boring qualities with best the BW technology is the integration of During the preacceptance of the complete long term repeatability results a highly reliable, crank­ and camshaft process at the BURKHARDT+WEBER ­ First­class operator ergonomics with boring technology proven as extremely factory in Reutlingen, Germany, all fixture short access distances successful and reliable since decades.

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