Maschinenfabrik ALFING KESSLER GmbH

All services are provided from a single source, all production is carried out on our premises

Simultaneous Engineering

Simultaneous engineering enables crankshaft optimisation to be performed before production commences.

Customer drawing/specification/product requirements

These customer specifications provide the basic data for our development departments within the simultaneous engineering process.

CAD/FEM simulation

We are usually able to use customer 3D data directly in our CAD/FEM system in order to simulate the demands stipulated for the crankshaft, e.g. bending and torsion fatigue strength. This is used to develop proposals for optimisation.

Developing processes to increase performance

The company's knowledge of crankshafts, which dates back more than a century, has resulted in recommendations in areas such as materials, heat treatment, surface treatment and the geometric design of the bearing journals.

Material search/optimisation

In our laboratories, we systematically test materials in terms of their behaviour under mechanical, thermal and chemical stresses and develop proposals for improvements in terms of the chemical composition or the use of alternative materials.

Prototypes

Our company has a separate prototype area in which all processes and process modifications, from engineering through to crankshaft production, can be implemented flexibly without any interruption to series production.

Component inspection: Endurance strength/bending/torsion

Using our in-house test benches, we can test crankshafts and crankshaft sections under realistic conditions and document the results on the computer. This enables us to generate detailed recommendations for future crankshaft deployment prior to series production.

Creation of drawing/optimisation/design

By the end of the engineering process, content originating from the customer specifications is transformed into an optimum solution that is ready for production and accompanied by comprehensive documentation. At the conclusion of this process, the 3D CAD crankshaft model is used to create flowcharts and drawings for the production processes.

Production process

The company's machine park covers all processes that are necessary for efficient production of crankcases.

CAD/CAM blank production

In forge construction, the 3D model of the crankshaft blank is derived from the 3D CAD crankshaft model. It is from this model that we derive the data for CNC production on our five-axle die-milling machining centres.

Various forging procedures for large crankshafts

At the company, we die-forge crankshaft blanks up to around 4.5 m in length. Larger crankshaft blanks up to around 9 m in length are transformed on presses using throw-by-throw forging.

Heat treatment

Our materials experts are able to configure the mechanical and technological material properties for various heat treatment processes such as normalising and tempering. This is done by providing a precise definition of the parameters for temperature, time and the cooling medium.

Tool inspection

The properties configured in the heat treatment are carefully checked and documented in our material laboratory prior to mechanical processing.

Preliminary and intermediate machining

Our computer-controlled CNC turning-milling machines can be used to perform precise and effective machining tasks such as turning, drilling, milling and thread cutting in just one clamping operation.

Surface treatment/hardening

The application of compressive residual stress by means of hardening and/or patented transforming procedures considerably increases the wear resistance and the service life. Our company offers a range of highly efficient processes in this area, particularly induction hardening. Our hardening expertise enabled us to establish our hardening division as early as 1952; this division now also delivers to external customers.

Final processing/assembly

All accessories such as counterweights and gear wheels are assembled and dynamically balanced as an overall system. The crankshafts are delivered onto the assembly line ready to be installed.

Washing/residual dirt analysis

Following a careful final inspection, the crankshaft systems are cleaned, preserved and packaged in fully-automated washing systems according to size. This prevents the ingress of even the smallest residual dirt particles as these processes take place in air-conditioned clean rooms.