Process solution for machining all types of connecting rods

In automotive engines, connecting rods are highly stressed components. To take account of downsizing and the reduction of CO2 emissions, connecting rods are also becoming increasingly lighter. The combination of new high-strength and innovative materials and modern production processes has brought the onset of connecting rods changing shapes and dimensions. To machine the ever increasing diversity, MAPAL now offers a solution for the complete process – whether wet or MQL machining on the transfer line or the machining centre.

When machining the connecting rod, the small connecting pin bore in particular is a challenge. Depending on the geometry, there are completely different drilling situations that cater for the connecting rod forms, flats and conical spherical surfaces. MAPAL has developed a modular tool concept for drilling from solid with indexable inserts that is especially for this type of machining. The introduction of new radially integrated, sintered indexable inserts each with four cutting edges are now applied to such instances.

MAPAL has uniquely placed the indexable inserts and chip spaces to meet the special requirements of the different drilling applications. The insert materials and composition has also been adapted. Among other things, the new CVD coating from MAPAL is applied to combine the previously opposing high ductility and high wear resistance parameters. This allows machining with significantly higher cutting speeds than before.

The tool body of the new range is made of an optimised material with significantly less vibration. A central coolant supply in the holder ensures the optimum supply of coolant directly to the cutting edges. This means a significant increase in process reliability and stability during bore machining.

As a complete supplier, MAPAL not only offers the optimum tooling solution, but also the toolholding chucks to perfectly balance the machining process. This includes hydraulic power chucks or the HTC with slim contours for reaching locations that are difficult to access. With the TOOLTRONIC mechatronic actuating tool, MAPAL also offers the appropriate solution for complex geometry machining, such as elongated bores or bores with oil grooves. MAPAL thus offers customers the complete process with minimum tool changes, which is specially geared to the prevailing conditions in each case.