Complete machining achieves a saving of 80–90% in the set-up time

As the energy sector continues to advance, efficient and high-precision methods of producing components are a crucial aspect. One area that requires special attention is the machining of crankshafts. Austria-based WFL Millturn Technologies is responding to this need by offering innovative solutions for the complete machining of crankshafts in small series.

A Millturn provides the best alternative to conventional production methods for the complete machining of crankshafts, including deep hole drilling of oil ducts or gearing. Based on many years of experience and the use of flexible and multifunctional complete machining centres, WFL can produce prototypes and small series of crankshafts efficiently. Whether for high productivity rough turning or precision pre-finishing — all crankshaft geometries can be completely machined in a Millturn from WFL.

The complete machining of crankshafts requires maximum accuracy and reliability. Conventional methods use several steps to machine crankshafts, with various specialised machines and processes coming into play. While this approach delivers a high output, it lacks flexibility and is therefore only suitable for large series. The production of crankshafts is a highly complex and relatively inflexible process both on highly specialised machines designed for series production and on all-purpose machines for small series and prototypes.

The use of Millturn complete machining centres together with efficient technologies allows WFL to combine the entire machining process in one machine in just a few clamping operations. Its machines can handle all the steps required to produce a crankshaft. A single machine carries out milling, boring, turning, deep hole drilling and measuring — from the blank to the nearly finished product. In addition to significantly reducing the production time, this also enhances the quality and precision of the crankshafts. Final heat treatment and the grinding of the crankshaft bearing and crankpin are the only separate processes.

Consistent quality
Complete machining eliminates the time-consuming process of moving between different machines and the set-up time this involves. This significantly boosts production capacities and reduces overall costs. At the same time, the machine’s high level of precision minimises the risk of errors and ensures the consistent quality of the crankshafts thanks to measurements carried out in the machine.

The potential for savings is considerable when machining crankshafts in a Millturn compared with conventional production on multiple machines. A 60% saving can be achieved in the process chain thanks to complete machining, and this figure is even 80–90% for the set-up time.

Machining crankshafts is a demanding process that not only requires perfect tools but also the relevant software to be successful. WFL’s cycle packages make crankshaft machining especially simple and cost effective. These cycle packages contain cycles for pre-roughing crankshaft bearings and bearing grooves, a web milling cycle and rounding of oil holes with radius cutter or corner rounding end mill.

Carrying out all machining steps in a single machine significantly shortens the production time. This eliminates the time-consuming process of moving from one machine to the next. Set-up times are reduced to a fraction of what they previously were. Integrating multiple machining steps into a single machine not only reduces labour and machine costs but also warehousing expenses for intermediate products.

Combined with efficient technologies, complete machining centres create the conditions for machining crankshafts with greater precision. The risk of errors and irregularities is minimised, resulting in components of a consistently high quality. Complete machining centre solutions can be tailored to specific customer requirements. Machines from WFL are suitable for machining various types of crankshafts and are capable of adapting to product modifications.

Using a single machine for the complete machining process speeds up the development of new models as the machine can be adapted in a flexible manner. Combining multiple machining steps in one machine reduces energy consumption and wasted material, creating the conditions for a more sustainable production process.