Productivity in the fast lane. Success with complete machining operations in the automotive industry

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Shannon Strickland
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1 Productivity in the fast lane Success with complete machining operations in the automotive industry

Economic production of components due to innovative tool solutions The automotive sector (automotive manufacturers and automotive supply industry) will be faced by extremely big

Global over-capacities, falling producer margins, strong consolidation pressure, model changes quickly following one after the other with an ever increasing number of variations,

2 Economic production of components due to innovative tool solutions The automotive sector (automotive manufacturers and automotive supply industry) will be faced by extremely big challenges in the coming years. Global over-capacities, falling producer margins, strong consolidation pressure, model changes quickly following one after the other with an ever increasing number of variations, consumers who are very demanding in terms of quality and prices: all these facts present the automotive companies with the great challenge of realising ever increasing performance at ever reducing prices. Increase in productivity, less cost pressure With some model lines, the value-added share is up to 75%, so it is understandable that the cost pressure is increasingly passed on to suppliers. The buyers require high-quality components and even complete assemblies at the best possible prices. We are the automotive industry s experienced partner; therefore, we fully understand the requirements and know how to meet them in the best way: with innovative tool solutions and sophisticated process chains in component production.

Complete machining operation with solutions

subsidiaries on all continents, we are able to

and experience of our automotive experts at

In close co-operation with our customers, we

component in terms of both engineering and

Increase in productivity and quality due to

all components and workpiece materials we offer

PCD cutting tool materials, tools and tool

and Xtra tec which have become the worldwide

3 Complete machining operation with solutions from A to Z As an international company with subsidiaries on all continents, we are able to offer our automotive customers the knowledge and experience of our automotive experts at every location. In close co-operation with our customers, we develop the best solution for each and every component in terms of both engineering and economic efficiency. Increase in productivity and quality due to benchmark tools For the complete machining of all components and workpiece materials we offer customers a comprehensive range of carbide and PCD cutting tool materials, tools and tool systems; including the product series Tiger tec and Xtra tec which have become the worldwide industry benchmarks for their capability to increase customers productivity by up to 100% in terms of turning, boring and milling applications.

PCD solutions for machining aluminium cylinder heads Chassis components,

increasingly made from aluminium; even diesel generators are made from

The advantages are evident: light weight, more vehicle miles travelled, less

For the precise and efficient machining of aluminium components we offer

4 PCD solutions for machining aluminium cylinder heads Chassis components, doors, rims and power train components such as cylinder heads, are increasingly made from aluminium; even diesel generators are made from aluminium. The advantages are evident: light weight, more vehicle miles travelled, less energy consumption, less pollutant emission. For the precise and efficient machining of aluminium components we offer customers a sophisticated programme of PCD and carbide tools. PCD cutter for roughing and finishing of head surface PCD cutter for roughing and finishing of control case surface PCD reamer for camshaft bearing gap

PCD cutter F2250 with integrated setting

bore PCD reamer for valve guide and seat

5 PCD cutter F2250 with integrated setting screw ensuring optimal axial concentricity from 63 mm diameter. PCD reamer for the parent component metal bore PCD reamer for valve guide and seat PCD reamer with precise indexable insert adjustment offering maximum boring precision (one or multi-fluted versions available). PCD monobloc cutter featuring a great number of teeth, for maximum axial and radial concentricity for superb surface quality and long tool life. PCD reamer for spark plug bore Solid carbide drill for flange bores Tap for flange bores The element-guided PCD tool meets the most stringent demands in terms of parallel alignment and service life.

Due to Tiger tec : efficient machining of grey cast iron crankcase The

or cast iron with vermicular graphite GJL).

for economically machining this material.

and they are able to increase customers productivity by up to 100% when it

6 Due to Tiger tec : efficient machining of grey cast iron crankcase The crankcase is the largest single component of the motor car. It is subject to extreme stress. Therefore, the component is usually made of cast iron (grey cast iron GJL or cast iron with vermicular graphite GJL). Our Tiger tec -cutting tool materials and Xtra tec -tool systems are ideal for economically machining this material. They provide the ultimate accuracy in terms of shape and surface quality, and they are able to increase customers productivity by up to 100% when it comes to turning, boring and milling operations. Tap for cylinder case bores Finishing tool for cylinder bores Profiling cutter for bearing shell (half round operation) CBN reamer for crankshaft bore

Roughing tool for cylinder bores Xtra tec

maximum feed rates and ultimate productivity

Xtra tec -close pitch milling cutter for

Finishing cartridges for Xtra tec -close

boring tool with PCD guide elements for top

Multi-function milling cutter for milling

side and face milling cutters and WALTER

The machining age is over. It s time to Tiger.

7 Roughing tool for cylinder bores Xtra tec -close pitch milling cutter F 4033 for maximum feed rates and ultimate productivity due to indexable inserts with 8 cutting edges. Xtra tec -close pitch milling cutter for roughing and finishing of head surface Finishing cartridges for Xtra tec -close pitch milling cutter (optional) Precision boring tool with PCD guide elements for top quality and long service life. Multi-function milling cutter for milling across holes Highly productive tool with 4 side and face milling cutters and WALTER system inserts for left- and right-hand application. Gang milling cutter for cheek face Tiger tec The machining age is over. It s time to Tiger. The perfect indexable insert for cast iron produces up to 75% increase in output. Contour cutting tool featuring distribution of cut and stable tangential inserts for maximum operational smoothness and process reliability.

Customised crankshaft machining The crankshafts of nodular graphite cast iron or steel

revolutions/minute, over many hours and without a break.

operations, even if the cost pressure is immense.

production of perfect crankshafts at competitive piece part costs.

8 Customised crankshaft machining The crankshafts of nodular graphite cast iron or steel alloy convert linear energy into rotational energy: at a speed of about 4,000 revolutions/minute, over many hours and without a break. Considering the huge forces applied, the component requires highly precise processing operations, even if the cost pressure is immense. Due to their high stock removal rates and long-life materials, our tools are ideal for the production of perfect crankshafts at competitive piece part costs. External milling cutter for bearing and cheek machining NOVEX CAPTO toolholder for post machining Xtra tec drill with exchangeable carbide tip Tools for central bores Indexable insert drill with four-edged insert

Internal milling cutter for bearing and cheek

carbide tip for high stability and reliable operation.

machining operations with productivity increases of

milling cutter, cartridgetype design, for extreme

Turn-turn broaching tool featuring robust indexable

Turn-turn broaching tool for bearing and cheek

9 Internal milling cutter for bearing and cheek machining Xtra tec -drill with perfectly fixed carbide tip for high stability and reliable operation. Xtra tec -face milling cutter for cast iron and steel machining operations with productivity increases of up to 100% Step drill for flange bores Internal milling cutter, cartridgetype design, for extreme metal cutting output, even under rough working conditions. Deep hole drill for oil bores Flexible all-rounder: Turn-turn broaching tool featuring robust indexable inserts for maximum operational security. Turn-turn broaching tool for bearing and cheek machining Tiger tec The machining age is over. It s time to Tiger. The perfect indexable insert now also for turning steel produces increases in output of up to 50% Toolholder (ISO and CAPTO versions) for the efficient roughing and finishing of shaft stubs.

Customised machining solutions for each and every component - due

different car components and assembly groups, customers expect us

Engineering department advise and care for our customers from the

10 Customised machining solutions for each and every component - due to WALTER tool systems According to the great variety of different car components and assembly groups, customers expect us to provide a suitable solution in every case, no matter what material is to be machined. Our experienced automotive specialists from the Global Engineering department advise and care for our customers from the worldwide automotive and automotive supply industry dealing with customers on site in every continent. PCD tools for gearboxes

11 From the analysis through to the planning and testing phase to the implementation of the optimised machining processes, there is just one key issue to us: developing the suitable machining solutions and how to increase customer s productivity and provide him with ever better quality thus substantially strengthening his competitive edge in the global market. Productivity in the fast lane The machining examples and tools presented in this brochure are part of our comprehensive range of cutting tool materials and tools for turning, boring, reaming and milling. Other machining examples will follow relating to complete machining operations in the automotive industry using WALTER tools. Tools for injection systems Tools for brake callipers

12 Headquarters: WALTER AG Derendinger Str. 53, D Tübingen Postfach 20 49, D Tübingen, Deutschland Tel , Fax Hotline: Productivity in the fast lane Europe WALTER DEUTSCHLAND Derendinger Straße 53, D Tübingen Tel , WERNER SCHMITT PKD-WERKZEUG AG Birkenstraße 8, D Niefern-Öschelbronn Tel , WALTER HARTMETALL GmbH Dottinger Straße 91, D Münsingen Tel , TDM Systems GmbH Derendinger Straße 53, D Tübingen Tel , WALTER (SCHWEIZ) AG Industriestrasse 6, CH-4513 Langendorf Tel , WALTER BENELUX N.V./S.A. Leuvensesteenweg, 510, Bus 40, B-1930 Zaventem Tel. (B) / Tel. (NL) info.wb@walter-ag.com WALTER GB LTD. Units Manor Side Industrial Estate, Walkers Road North Moons Moat, GB-Redditch, WORCS., B98 9HE Tel , info.wgb@walter-ag.com WALTER USAP S.R.L. I Fino Mornasco (CO), Via Garibaldi, 118 Tel , info.wu@walter-ag.com WALTER FRANCE Rue Max Christen, F Soultz-sous-Forêts Tel , service.france@walter-tools.com WALTER TOOLS IBERICA S.A.U. La Selva 18, Parc de Negocis Mas Blau E El Prat de Llobregat Tel , info.wtu@walter-ag.com America WALTER USA, INC. N22 W23855 RidgeView Parkway West, Suite 100 Waukesha, WI 53188, USA Tel , service.usa@walter-tools.com WALTER DO BRASIL Ltda. Rua Campinas, 77, Jardim Leocádia CEP Sorocaba SP, Brasil Tel , walterbr@walter-br.com.br Asia and Oceania WALTER WUXI Co. Ltd. 531 West Xihu Road, Wuxi, Jiangsu, , P.R. China Tel service.china@walter-tools.com WALTER AG SINGAPORE PTE LTD 25 Pandan Crescent #01-10 TIC Tech Centre, Singapore Tel , info.wsi@walter-ag.com Co. Regn No: H WALTER KOREA LTD. 605 BL 23-2 L, Banwol Industrial Complex , Shingil-dong, Ansan, Kyungki-do, Korea, Tel , info.wko@walter-ag.com WALTER TOOLS INDIA Pvt. Ltd. Mumbai Pune Road, Dapodi, Pune , India Tel , service.india@walter-tools.com WALTER TAIWAN 3F-2, No. 308, Chung Cheng Road, LuChu Township Taoyuan County 33861, Taiwan R.O.C. Tel , info.wtw@walter-ag.com WALTER (THAILAND) Co. Ltd. 4 th Floor, Galaxy Place, 149 Nonsee Road, Yannawa District, Bangkok 10120, Thailand Tel , info.wth@walter-ag.com Printed in Germany (07/2006) WALTER CZ spol.s.r.o. Blanenská 1289, CZ Kurim Tel , info.wcz@walter-ag.com WALTER POLSKA sp.z.o.o ul. Taborowa 20, PL Warszawa Tel , info.wpo@walter-ag.com WALTER HUNGÁRIA Kft. H-1117 Budapest, Budafoki út 209 Tel , info.whu@walter-ag.com MONTANWERKE WALTER Ges.m.b.H Johannesgasse 14, A-1015 Wien Tel , info.mww@walter-ag.com SC MONTANWERKE WALTER SRL Filiala Timisoara Romănia RO , Timisoara, jud. Timis Str. Stefan cel Mare Nr. 56, Corp. B Et. 1 Tel , info.wro@walter-ag.com Podružnica Trgovina Slovenia Ptujska cesta 13, SL-2204 Miklavž na Dravskem Polju Tel , info.wsl@walter-ag.com Representant Slovensko Dlhá 118, SK Nitra Tel , info.wsk@walter-ag.com Branch Office Russia Sinopskaya nab. 50A, Sankt Petersburg, Russia Tel , info.wru@walter-ag.com WALTER AUSTRALIA PTY. LTD Overseas Drive, Noble Park, Victoria, Australia 3174 Tel service.australia@walter-tools.com WALTER NEW ZEALAND Ltd. PO Box 2446, Christchurch, New Zealand Tel info.wnz@walter-ag.com

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