Maschinenfabrik ALFING KESSLER GmbH

Interlinked production line with CNC processing centres and gantry loaders

Series production

In series production, we have focused on forged crankshafts with a delivery volume of between 5,000 and 170,000 crankshafts a year for each type. Our total volume is approximately 300,000 crankshafts per year. Whereas the large crankshaft forgings are manufactured in our in-house forge, we obtain the automotive crankshaft forgings from external press forging shops.

Preliminary work, hardening and forging is performed on the shafts in various production lines that handle crankshafts for in-line engines, six-stroke V-engines and twelve-stroke V-engines. This also enables us to manufacture highly complex split-pin crankshafts in large quantities. The bearing surfaces and fillets are processed using the latest tape finishing machines,
which is what allows us to achieve the necessary levels of surface precision and form tolerance.

Despite the high degree of automation, additional visual checks are also carried out. The ready-to-install crankshafts are supplied by means of just-in-time delivery.

TestMilling bearing journals in an external form milling machine with two separately controlled tools.

A wide range of chain and gear wheels can be manufactured depending on the specification.

A look inside the workspace of the BAZ KW 600 induction hardening machine: cutting-edge hardening machine design, fully-enclosed workspace, cycle time approx. 60 s.

With the help of the first CNC pendulum stroke forging machine for car crankshafts, ALFING was ready to completely transform the forging principle as early as 1996. The crankshaft was then tensioned around the centre of the axis and the oscillating grinding wheel followed the movement of the big end bearing journal.

Robots for loading and unloading processing centres on a production line for automotive crankshafts.

Fully-automated, dynamic balancing machines are loaded and unloaded mechanically.

With the help of automatic band finishing machines, we are able to achieve the necessary levels of surface precision and form tolerance.

Following mechanical processing, the crankshafts and their oil channels are subjected to high-pressure cleaning up to 750 bar in a multi-chamber system. Automatic loading systems and robots assume control for handling the shafts.

Fully-automated measuring and laser encoding.

At the request of the customer, the crankshaft can be issued with data matrix codes for the purpose of secure identification.