Crankshaft Milling Machines FKD American GFM Corporation 1200 Cavalier Boulevard Chesapeake, Virginia 23323 Telephone No. Area Code 804-487-2449, Telex No.:823414 cay-9 P.1.00Crankshaft Milling Machines FKD with Internal Mil ig Cutters ‘The design of GFM milling machines Is protected by domestic and foreign patents. Copyright 78-07-30, rwprodvnd with te Parminion of Anarian GFM Corporation MACHINE TOOLS, TR-1 OTHERS (AMERICAN GFM) cay-9 Reproductions Distributed by Equipment Guide-Book Company, Plo Alto, California 94303 P.2.00cay-9 Crankshaft Milling Machines FKD with Internal Milling Cutter ‘The machines of this type are particularly suitable for machining large batches of one or a small variety of crankshafts. The internal milling cutter achieves very high metal removal rates and the simple design, without NC control, is ideal for large batch production. Journals and pins can be milled. The crankshaft rotates. The copying movement of the milling Slide for machining pins Is achieved mechanically. Dogs and limit switches control the remain- ing movements and paths of the slides. Compared with the type FKP machines, which are ‘equipped with NC control in three axes for universal application, a considerable price advantage results from this simplification. In addition, set-up and operation of the ‘special skill by the operator. The longer resetting time compared with the NC equipped machine is of no great Importance for large batch production. Shortest milling times Suited for journals and pins Minimum grinding stock Particularly advantageous for large series production Fully automatic or with manual loading Low tooling costs ple set-up, operation and maintenance Low space requirement MACHINE TOOLS, TR-1 OTHERS (AMERICAN GFM) P,3.00 Reproductions Distributed by Equipment Guide-Book Company, Palo Alto, California 84303MACHINE TOOLS, TR-1 Example Processing of a truck crankshaft truck crankshaft, 6-throw illing of 5 journal 85 mm @ x 42 mm wide milling time 7.4 min. chip weight 8.3 kg) truck crankshaft, 6-throw milling of§ pins 76 mm @ x52 mm wide milling time 9 min. chip weight 13.5 kg Machining of a crankshaft with 2 riling cutter 38 mm wide in one operation, ‘machined in 5 journals 67 mm @ x39 mm 6 pins 76 mm 0 x 39mm Journals are machined with 1 plunge-cut Pine are machined with 1 plunge-cut ‘Total miling ime 9.2 min.. OTHERS (AMERICAN GFM) cay-9 ‘Book Company, Palo Alto, California 94303 Reproductions Distributed by Equipment GiDesign of Machine Standard design with one milling slide for machining the journals and pins. The crankshaft, which rotates during machining, is clamped between the headstock (ill. 1) and a movable tallstock and is driven on both ends. The cutter, with internally arranged blades, is mounted on the front face of the drive drum which, in turn, is mounted on the milling slide. The milling slide performs the infeed move- ment transversely to the workpiec and during machining of the pins it effects the copying movement. It traverses on the longitudinal slide, which moves the milling slide on the bed from plunge-cut to plunge-cut. The crankshaft Is indexed in such a way that the next pin to be machined Is in the correct angular position, relative to the copying template. When machining journals this indexing procedure can be used in order to obtain the same plunge-cut path for all journals. All slideway liners are coated with synthetic resin plastic. The ways are hardened and ground. Fig. 1 3 Cteratge § Conan! side cay-9 MACHINE TOOLS, TR-1 OTHERS (AMERICAN GF) P.5.00 Reproductions Distributed by Equipment Gude Book Company, Pato Alto, California 94303A special synthetic resin with excellent anti-stick-slip properties is used. This guarantees smooth running even at lowest feed rates. For supporting the workpiece, a self-centering steady rest is provided which moves in con- junction with the longitudinal slide. When traversing from plunge-cut to plunge-cut the steady rest opens and closes automatically. ‘The plunge-cut positions are approached automatically and controlled either by dogs and limit switches or by simple point-to-point NC equipment. For changing workpieces, the longitudinal slide moves the drive drum and cutter over the extended neck of the headstock which carries the chuck. Crankshafts can then be very easily unloaded and loaded into the chucks from above. The chucks can be manually or power actuated, By equipping it with auto-loading equipment, the machine and the power chucks per- form fully automatically. P.6.00 MACHINE TOOLS, TR-1 OTHERS (AMERICAN GFM) cay-9 Reproductions Distributed by Equipment Guide-Book Company, Plo Alto, California 94303,_ ee eee The cutters are equipped with tungsten carbide throw-away blades. Basically, by reversing them the blades can be used eight times, in special cases up to sixteen times. When all eight cutting edges have been used the blades are replaced. The nests for the blades are so accurate that the latter can be turned or replaced without the necessity for any further resetting. In special cases, for machining the main bearings only, a double cutter can be used which permits simultaneous machining of two journals. In plunge-cut position A of the double cutter, the two journals 5 and 6 have already been milled. Journals 3 and 4 are milled in position B and journals 1 and 2 in position C. Fig. 2 4.7, Journate ALIIE Bitngereut postions cay-9 MACHINE TOOLS, TR-1 OTHERS (AMERICAN GM) P.7.00 ‘Reproductions Diswibuted by Equipment Guide-Book Company, Pao Alto, California 94303Technical Data Domestic and foreign patents pending Alteration rights reserved Crankshat: ‘Swing diameter max.mm 200 200 300 300450 Length mm 1200 1500 1500 1500 2500 ‘Other lengths on request FKD 201 20/2 301 30/2 45 OO Cutter Stide: Number 1 ait 8 4 Rapid mm/min, 5000 $000 5000 000 4000 Plunge-cutt ‘mm/min, 0-600 0-600 0-800 0-600 0-600 —_na nanan Tongituainal Side: Rapid traverse Oe Oe ‘Werkpiece rpm: iting pm 06 08 0S OS Indexing pm tO ees Cutter head: Cutting diameter mm 290-230-320 $20 470 Cutting speed. mvmin, = 112.«112,—«12—s 112100 25125 125 125112 140 140 140140125 ‘Miling motor 45 2x45 752x680 90 “4500 5200 5400 6250 7600 2100 2100 2400 2400 3400 4650 1650 2000 2000 2500 020 1020 1250 1250 1650 Height Helght of centers __ rr rr 7s 236 21 908 528 "Approx. weight MACHINE TOOLS, TR-1 OTHERS (AMERICAN GPM) P.8.00 Reproductions Distributed by Equipment Guide-Book Company, Palo Alto, California 94303 cay-9Special Equipment ‘Special design with one milling slide for machining the pins of one- and two-throw crankshafts (ill. 3). On these machines, the crankshafts are clamped in such a way that the pin to be machined lies concentric to the axis of the workpiece spindle. The milling slide does not re quire any copying movement and performs plunge-cutting motions only. For workpiece change, the longitudinal slide retracts the milling cutter from the workpiece and then moves it into the precise plunge-cut position again. On two-throw crankshafts, the pins are machined succes- sively by resetting in the chuck. 1 Maing ste Fig. 3 nici sie 4 Henao 1 cater cay-9 MACHINE TOOLS, TR-1 OTHERS (AMERICAN GPM) P.9.00 Reproductions Distributed by Equipment Guide-Book Company, Pala Alto, California 94303Special Equipment Special design with two milling slides for simultaneous machining of two pins. Ill. 4 shows the design of such a machine. In the example, on a five bearing four-throw crankshaft pins | and Ill are processed simultaneously followed by pins Il and IV. The crankshatt is indexe ought into the correct angular position to the copying tempiate. Between the milling ‘cutters, the crankshaft is supported on two points by a double steady rest. The steady rest travels with the longitudinal slide and during positioning it opens and closes automatically. Each longitudinal slide is equipped with a separate copying attachment. For workpiece change, the headstock also has an extended neck in order that the longitudinal slide 4 can move the milling cutter over the chuck of the headstock. P.10,00 MACHINE TOOLS, TR-1 OTHERS (AMERICAN GPM) cay-9 ductions Distributed by Equipment Guide-Book Company, Pao Alto, California 94303Copying Control The milling slide (il. 5) with milling cutter is moved horizontally on the longitudinal slide by means of a hydraulic cylinder. The milling template is secured to the milling slide and has the same radius Ras the cutting radius of the cutter. The copying mechanism drive is supported in the longitudinal slide and is driven synchronously with the crankshaft. For milling pins, the pin template is mounted on the copying drive eccentrically by a distance equal to the throw radius of the crankshaft. For machining the main bearings, the journal template is set concen- {rically to the copying device. The pin or journal template has the same diameter pin or journal to be milled. During copying, the milling slide cylinder is driven by the cutter template, following the rotating pin template. For increasing the accuracy of the milled pin or journal, the hydraulic force is adjusted to suit the changing direction of the slide friction. The individual phases of the copying process when machining a pin are shown diagrammati- cally by il. 6. To illustrate this more clearly, the stroke of the crank and the copying drive are ‘shown in the same plane. Fig. 5 ea 2 cay-9 MACHINE TOOLS, TR-1 OTHERS (AMERICAN GF) P.11.00 Reproductions Distributed by Equipment Guide-Book Company, Palo Alto, California 94303a) Starting position. The cutter is concentric to the crankshaft. The milling template is re- tracted from the pin template. b) The milling slide with the cutter and the milling template approach the workpiece in rapid traverse along the path s;, changing over to plunge-cut feed. ©) Path s, is the plunge-cut between the web faces of the crankshaft with hydraulically con- trolled feed. 4) After completion of the plunge-cut path, the workpiece and the pin template start to rotate synchronously. The hydraulic pressure holds the milling template and the pin template in constant contac e) The milling process is completed after one revolution of the workpiece. The crankshaft remains stationary and the rapid return traverse of the milling slide on path s; commences. f) At the end of the cycle, the cutter is again at the starting position. The longitudinal slide ‘moves the milling slide to the next plunge-cut position. Stat postion «= Rapldtavarse $;—Plungecat fed Copying Endot ai Sarit veelton ‘evoition tion — ‘Stwonaiece 5) Rapid rtm P.12.00 MACHINE TOOLS, TR-1 OTHERS (AMERICAN GF) cay-9 ‘Reproductions Distributed by Equipment Guide Book Company, Palo Alt, California 94303,