Cutting Tools and Chucks Optimized for Machining Connecting Rods

Connecting rods are highly stressed engine parts. To take account of downsizing and the reduction of CO₂ emissions, connecting rods are also becoming increasingly lighter. This is achieved on the one hand through the use of high-strength and innovative materials, and on the other hand through modern production processes. This also changes the shape of the connecting rods and the variety of shapes increases. MAPAL offers the complete process for machining different types of connecting rods – whether on the transfer line or the machining center, as well as for wet or MQL machining.

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. For example, for various connecting rod forms, flat, deep and conical spherical surfaces or for existing forging noses. MAPAL has developed a modular tool concept for drilling from the solid with indexable inserts especially for this type of machining. Radially integrated, sintered indexable inserts each with four cutting edges are used here.

The placement of the indexable inserts and the chip flutes are adapted to the special requirements of the different drilling situations. The cutting materials are also adapted. Among other things, the new CVD coating from MAPAL is used, which combines the previously opposing high ductility and high wear resistance parameters and thus allows machining with significantly higher cutting speeds than before.

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

As a complete supplier, MAPAL not only offers the optimal tools, but also chucks perfectly tailored to the respective type of machining, including hydraulic power chucks or the HTC with slim contour for locations that are difficult to access, such as the oil bore. With the mechatronic actuating tool TOOLTRONIC, MAPAL also offers the appropriate solution for complex geometries, for example bores that are not circular or shaped bores with an oil groove. MAPAL thus offers customers the complete process with minimum tool changes, which is specially geared to the prevailing conditions in each case.