RFK crankshaft production systems

External milling of crankshafts

External milling is a flexible and productive method used primarily in the mass production of small to medium-sized crankshafts. The RFK crankshaft production systems from HELLER are for machining concentric and eccentric bearing points, faces, external diameters and special contours in a highly productive manner – often in just one setup.

  • cutting speed is generated by the tool
  • feed rate is generated by workpiece rotation
  • externally toothed tools are used
  • the profile to be milled is replicated in the tool
  • two interpolating NC-axes are used to machine crankpins, positioned eccentrically to the workpiece centre and/or concentrically to the crankshaft main bearings
  • a rotary axis turns the workpiece at feed speed and the milling unit(s) is/are followed by one/two linear axis/axes
  • The plunge cut to the journal diameter is carried out by the linear axis of the milling unit with stationary rotary axis or with a spiral movement using interpolation of the two axes. During the plunge, the cheek faces can be completely or partially machined.
  • in order to withstand cutting forces, the workpieces are clamped and supported by two hydraulic clamping chucks with electrically synchronized rotation and by an additional steady rest which can be positioned via NC programming
  • this steady rest is set on a separate guideway below the milling slides for unrestricted support positioning within the travel paths.
  • machining with one or two milling units is possible
  • machining of bearing diameters and undercuts in one operation is possible
  • simultaneous machining of mains and pin profiles is possible
  • use of gang cutter is possible
  • accurate face machining eliminates the need for rough-grinding

The following features can be machined (also in combination):
mains, pin bearings, main and pin bearings in one setup, cheek faces and cheek outer diameters, undercuts, cheek profiles

Technical Data

Product selection RFK 10RFK 15RFK 30
max. Workpiece length mm 5006001.250
max. Swing diameter mm 160200290
Tool diameter mm 700700800
max. Power kW 306080

RFK crankshaft production systems

Internal milling of crankshafts

The internal milling of crankshafts is a productive machining method offering the best possible stability and machining accuracy with the highest stock removal rate. Thanks to the special machine component arrangement, the HELLER RFK crankshaft production system is able to accomplish even the most difficult machining tasks for very low part costs. Special tool concepts allow simple setting activities, as well as a fast tool change.

  • cutting speed is generated by the tool
  • feed rate is generated by workpiece rotation
  • internally toothed tools are used
  • because the tool completely surrounds the workpiece, the tool inside diameter is greater than the max. workpiece swing diameter and the clamping chuck diameter
  • the profile to be milled is replicated in the tool
  • two interpolating NC-axes are used to machine crankpins, positioned eccentrically to the workpiece centre and/or concentrically to the crankshaft main bearings
  • a rotary axis turns the workpiece at feed speed and the milling unit(s) is/are followed by one/two linear axis/axes
  • The plunge cut to the journal diameter is carried out by the linear axis of the milling unit with stationary rotary axis or with a spiral movement using interpolation of the two axes. During the plunge, the cheek faces can be completely or partially machined
  • in order to withstand cutting forces, the workpieces are clamped and supported by two hydraulic clamping chucks with electrically synchronized rotation and by an additional steady rest which can be positioned via NC programming
  • the steady is arranged on the guideway below the milling slide and, in the case of a two-spindle machine, is located between two milling units
  • machining with one or two milling units is possible
  • machining of bearing diameters and undercuts in one operation is possible
  • simultaneous machining of mains and pin profiles is possible
  • use of gang cutter is possible
  • accurate face machining eliminates the need for rough-grinding

The following features can be machined (also in combination):
mains, pin bearings, main and pin bearings in one setup, cheek faces and cheek outer diameters, undercuts, cheek profiles

Technical Data

Product selection RFK 100RFK 150RFK 300
max. Workpiece length mm 5006001.250
max. Swing diameter mm 160200200
Tool diameter mm 230275275
max. Power kW 306060

DRZ crankshaft production system

Turning-chasing of crankshafts

The turning-chasing of crankshafts is a highly productive machining method used primarily for mass production. HELLER DRZ crankshaft production systems permit maximum machining accuracies with high machining flexibility and long tool change intervals, coupled with extremely short chip-to-chip times.

  • cutting speed is generated by the tool
  • feed rate is generated by workpiece rotation
  • plunge turning with standard plates and a chasing operation, developed and patented by HELLER for this purpose, allow efficient and highly accurate machining of various diameters and faces, positioned concentric to the rotary axis
  • extended tool operation times through the use of duplicate cutting edges
  • fast cutting edge change for extremely short chip-to-chip-times
  • automatic single cutting edge measurement in two directions
  • one set-up for all machining all concentric diameters (mains, undercuts, recesses, flange and stub-end)
  • robust machine design allows heavy-duty cheek face cutting or cutting of the cheek outer diameter
  • workpieces are clamped with two hydraulic, electronically synchronised clamping chucks; retractable clamping jaws available as an option
  • optional workpieces for absorbing the cutting forces can be supported by means of an NC-controlled steady rest
  • this steady rest is set on a separate guideway for unrestricted support positioning within the travel paths
  • machining with either one or two turning-chasing units is possible
  • accurate face machining eliminates the need for rough-grinding

The following features can be machined (also in combination):
mains, undercuts and grooves, thrust bearings, flange diameters, stub-end diameters, concentric profiles, pin bearings by means of eccentric clamping (custom design), cheek faces and cheek outer diameters, chamfers (also eccentric edge)

Techncial Data

Product selection DRZ 10DRZ 15DRZ 30
max. Workpiece length mm 5006001.250
max. Swing diameter mm 160200280
Tool diameter mm 700700700
max. Power kW 304848

MCC 15 crankshaft production systems

Milling, boring, tapping crankshafts

The range of HELLER MCC 15 crankshaft production systems covers all machining operations that have to be executed at the crankshaft with processes such as boring, milling or tapping – including with special features, such as for deep hole drilling or for making relief bores.

  • tried and proven HELLER machining centre for heavy-duty cutting in the form of a basic machine with the corresponding series components
  • machining unit can be traversed transversely (X-axis) and vertically (Y-axis) via NC-axes
  • traversing occurs in the longitudinal direction (Z-axis) by means of two synchronously driven ball drives that move the NC-rotary table
  • workpieces rotated into the respective machining positions for type "C" and "E" via the NC rotary table (B-axis) and for type "D" via the NC rotary axis (A-axis) and the NC rotary table (B-axis)
  • all workpiece features are created via the HMI by means of user-friendly input screens
  • very good view into the work area through large operating doors and viewing window
  • easy to load the machine by swivelling the fixture
  • excellent accessibility for all maintenance and repair work
  • up to three workpieces can be loaded and unloaded during machining
  • use of multi-spindle heads possible
  • machine can be designed for MQL or KSS (minimum quantity lubrication or cooling lubricant)

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

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

MCC 15-D (drilling): pilot bores, transverse bores, directional bores, chamfers at the bore exits, weight-relieving bores

MCC 15-E (finish-machining): needle bearing bore, flange bores, gauging bore, bores at the sprocket seat, bores at the journal end

Technical Data

Product selection MCC 15-CMCC 15-DMCC 15-E
Number of spindles 2/32/32/3
max. Workpiece length mm 700625700
max. Swing diameter mm 200200200
max. Power/Spindle kW 31/2231/2231/22

RFN camshaft production systems

External milling of camshafts

Camshaft machining – often directly from round material – requires the highest possible stock removal rate to be cost efficient. This places the toughest demands on the machining operation. HELLER RFN camshaft production systems put you on the safe side: you produce with high accuracy for optimal part costs.

  • cutting speed is generated by the tool
  • feed rate is generated by workpiece rotation
  • externally toothed tools are used
  • cutter diameter can be used for most hollow cam profiles.
  • the profile to be milled is replicated in the tool
  • two interpolating NC axes are used for machining of cam profiles
  • a rotary axis turns the workpiece at feed speed and the milling unit(s) is/are followed by one/two linear axis/axes
  • the plunge cut to the cam profile is carried out by the linear axis of the milling unit with stationary rotary axis or with a spiral movement using interpolation
  • in order to withstand cutting forces, the workpieces are clamped and supported by one or two hydraulic clamping chucks with electrically synchronized rotation and by an additional steady rests, which can be positioned via NC programming
  • steady rests are set on a separate guideway below the milling slides for unrestricted support positioning within the travel paths
  • machining with one or two milling units is possible
  • machining of cam profiles and chamfers in one operation is feasible
  • use of gang cutter is possible
  • radial alignment through bore or groove
  • accurate machining of journals makes rough ("green") 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, interspaces between the cams (special design)

Technical data

Product selection RFN 10
max. Workpiece length mm 1.250
max. Swing diameter mm 100
Tool diameter mm 450
max. Power kW 37

Downloads

heller-crankshafts-camshafts-productionsystems-rfk-drz-mcc15-rfn_en.pdf
Product brochure
Crankschaft/camshaft production systems RFK/DRZ/MCC 15/RFN
3.1 MB

At a glance, our Download Centre offers an extensive range of information materials about our company, our products and services for you to download.

Contact

Sales & Services

Do you have questions about our products and services? Please get in touch with us, we are here for you! Benefit from our global HELLER network with knowledgeable sales and service contacts located in your region.

Find your nearest personal contact.

No results could be found.

You might also be interested in

HELLER Newsletter

Register now!

The HELLER Newsletter provides you with information about all current topics concerning our company, our products and services as well as upcoming trade shows and events. Register now to make sure you never miss any news from the HELLER Group!