Rolling Forged Camshaft
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Transcript of Rolling Forged Camshaft
![Page 1: Rolling Forged Camshaft](https://reader033.fdocuments.net/reader033/viewer/2022061116/54654138b4af9f37068b45ef/html5/thumbnails/1.jpg)
The advantage of rolling forge
• High Efficiency
One or two parts are finished in one rotation of the roller, 2-12 parts are finished one minute. It can save the machining cycle time also.
• Save Material
Rolling forge made by wedge rolling technology have high precision and can be made with various shapes like tapered flange or right-angle flange. It saves 10-20% material than die forging and 20-40% than bar cutting in average.
• Good Quality
The part's mechanical property can be raised by 25% synthetically resulting from complete steel fiber and the grain refining after rolling.
• Lower cost
For the above reasons, the cost can be reduced 20-40% comparing with the traditional bar machining.
![Page 2: Rolling Forged Camshaft](https://reader033.fdocuments.net/reader033/viewer/2022061116/54654138b4af9f37068b45ef/html5/thumbnails/2.jpg)
Area: 6500 m2
Machine quantity: 60 machines,3 forge lines
Employees: 150 Shifts: 3
Production: 1800,000 pieces a year
Rolling Forge Machine
Rolling forge Rolling forge raw camshaft
H1200 rolling forge machine
![Page 3: Rolling Forged Camshaft](https://reader033.fdocuments.net/reader033/viewer/2022061116/54654138b4af9f37068b45ef/html5/thumbnails/3.jpg)
Rolling Forge Workshop
![Page 4: Rolling Forged Camshaft](https://reader033.fdocuments.net/reader033/viewer/2022061116/54654138b4af9f37068b45ef/html5/thumbnails/4.jpg)
material checking
cutting
induction heating
normalizing
rolling forge
Rolling forge process
straightening&detecting
raw bar of camshaft
![Page 5: Rolling Forged Camshaft](https://reader033.fdocuments.net/reader033/viewer/2022061116/54654138b4af9f37068b45ef/html5/thumbnails/5.jpg)
Finished machine
Cam grinding machine
JUNKER JUN5000/10
Made in Germany
2002
Cam grinding machine SCHAUDT CF-61 Made in Germany 2002
INSTRUMENT ADCOLE MODEL-911 Made in USA 2002
Area:8000 m2
3 produce lines
Employees: 120 Shifts: 3
Production: 500,000 pieces a year
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Machining Workshop Overlooking
![Page 7: Rolling Forged Camshaft](https://reader033.fdocuments.net/reader033/viewer/2022061116/54654138b4af9f37068b45ef/html5/thumbnails/7.jpg)
Raw bar of camshaft
lobe milling rough grindi
ng
induction hardening& tempering
Finished grinding
center drilling& turning
Crack detecting
Checking
camshaft machining process
marking& packing
![Page 8: Rolling Forged Camshaft](https://reader033.fdocuments.net/reader033/viewer/2022061116/54654138b4af9f37068b45ef/html5/thumbnails/8.jpg)
Hardness measurement HRC,HB,HV
Future FV700,Japan
Metallography Microscope
Olympus PMG3 Japan
Electronic strength instrument
Made in China
Checking machine
![Page 9: Rolling Forged Camshaft](https://reader033.fdocuments.net/reader033/viewer/2022061116/54654138b4af9f37068b45ef/html5/thumbnails/9.jpg)
3D-Coordinate measuring machine
Made in china
Instrument for camshafts
ADCOLE MODEL-911
Made in USA
Checking Machine
![Page 10: Rolling Forged Camshaft](https://reader033.fdocuments.net/reader033/viewer/2022061116/54654138b4af9f37068b45ef/html5/thumbnails/10.jpg)
Comparison with the traditional machining
Example Size of
lay-off Weight
(kg) Raw’s turning Time
Mechanical character
Steyr 6 cyl.
camshaft
Ф65×715 18.63 16.5min.
Bar Ф65×985 25.64 24.5min.
Results Material Save 27.3%
Caterpillar6 cyl.
camshaft
Ф65×615 15.89 12min.
φ65×876 22.81 19min.
Results Material Save 30.3%
efficiency improve 48%
Rolling forge
Bar
The mechanical character improve 25% ;Metallograph refine than the bar.
Rolling forge
efficiency improve 58%
![Page 11: Rolling Forged Camshaft](https://reader033.fdocuments.net/reader033/viewer/2022061116/54654138b4af9f37068b45ef/html5/thumbnails/11.jpg)
Sample
Cutting Rolling forge Turning
Steyr 6 cyl. Camshaft
Steel bar:φ65×715
Raw camshaft φ65×985
Semi-finished camshaftφ61.8×980
![Page 12: Rolling Forged Camshaft](https://reader033.fdocuments.net/reader033/viewer/2022061116/54654138b4af9f37068b45ef/html5/thumbnails/12.jpg)
Caterpillar 6 cyl. Camshaft
Sample
Cutting Rolling forge Turning
Steel bar:φ65×615
Raw camshaft φ65×876
Semi-finished camshaftφ62.2×872
![Page 13: Rolling Forged Camshaft](https://reader033.fdocuments.net/reader033/viewer/2022061116/54654138b4af9f37068b45ef/html5/thumbnails/13.jpg)
Different state camshafts
Rolling forged
Turned
Lobe milled
Lobe grinded
Material : SAE1080 CF53 45 20Cr …