alfing kessler gmbh large crankshafts alfing … · maschinenfabrik alfing kessler gmbh large...

MASCHINENFABRIKALFING KESSLER GMBH

LARGE CRANKSHAFTS

www.alfing.de

ALFING Large Crankshaftsfor ships, generators, machines

and special-purpose vehicles

FULL SPEED AHEAD

Karl Kessler Auguste Kessler

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„As an engineer I travelled to different coun-

tries in Europe and North America and I be-

came aware that a high-quality product such

as an internal combustion engine crankshaft

would be a suitable product for manufacture

in my German homeland. With this in mind I

returned from North America.“

With the ambitious aim „... of developing and manufacturing more robust and wear resistant crankshafts ...“, Karl Kessler foun-ded his own company in 1911.

This remains our ambition still today.

In the meantime the company is a leader in technology and with over 1350 employees one of the largest independent specialist manufacturers of high-quality crankshafts and induction hardening machines world-wide.

But that‘s not all. We are continuing to expand.

With crankshafts ranging from 300 to 8000 mm in length, ALFING covers a very wide engine spectrum.

In the beginning, large crankshafts were ALFING‘s main focus:

For example the aircraft engines in the Zep-pelin airships made ALFING‘s name known all over the world.

As early as 1932 ALFING became closely in-volved in car racing: 6 cylinders, 300 HP and more than 235 km/h. > Mercedes-Benz SSKL > Auto-Union ... and others were soon to follow.

And in their engines: The world‘s first racing crankshafts ...

... from ALFING.

Ever since, one can hardly think of car engines without thinking of ALFING crank-shafts.

We are experts in the manufacture and harde-ning of crankshafts for automotive, racing and large engines for almost every conceivable application and major engine manufacturer worldwide.

ALFING is the partner for its customers‘ crankshafts over the entire life of the engine:

From planning, optimisation, project manage-ment, process development, logistics, quality assurance, material procurement, forging, heat treatment, mechanical machining, surface treatment, assembly, testing through to after-sales service and support.

This is how we have become global market leader in high-performance crankshafts and hardening equipment.

Karl Kessler on the 25th anniversary of the company in 1936

Crankshafts for more power

Crankshafts: That‘s our business!


AUTOMOTIVE CRANKSHAFTSLARGE CRANKSHAFTSHARDENING EQUIPMENT

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At home in engines worldwide

History of theMaschinenfabrik ALFING Kessler

1911 Founding of the Maschinenfabrik ALFING Kessler GmbH by Karl Kessler (1880-1946)1913 Delivery of the first case-hardened crankshafts1932 Focus on the production of crankshafts for aircraft engines for airships and transport planes1935 Establishment of the special-purpose forge for crankshaft forgings1946 Death of company founder Karl Kessler1947 Auguste Kessler takes charge of the company1951 Manufacture of the one millionth crankshaft1952 First induction hardening machine for crankshafts1960 Death of Auguste Kessler1970 New production shops for large crankshafts1990 Expansion of the production facilities for automotive crankshafts1995 Establishment of a separate production department for motor sports and prototype crankshafts2003 Reorganisation and targeted market segmentation of the company2004 Expansion of automotive crankshaft production2005 Expansion of large crankshaft production2006 Manufacture of the seven millionth crankshaft 2007 ALFING again invests in further expansion of crankshaft manufacture

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Energy and mobility are fundamental cor-nerstones of business and the economy.

Worldwide.

This calls for high-performance engines on land, on sea and in the air.

And high-performance crankshafts ...

... that‘s our job.

The continuously increasing demand for greater engine performance and efficiency calls for higher performance components – starting with the crankshaft.

That is why ALFING has become a specialist in the surface treatment of crankshafts to increase performance.

Whether powerful diesels for Sports Utility Vehicles (SUV), high-speed engines for Formula 1, stationary engines for power generation or ship diesels:

„Optimal continuous power“ is what our customers demand from their crankshafts.

To achieve this we offer:

> development support > process reliability > high-quality manufacturing > fatigue strength > wear resistance > performance enhancement ...

... because that‘s what our customers expect.

Whatever the make of the engine ...ALFING is usually inside



ALFING: Partner ...

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… for perfect mobility

Hardening machines based on modular machine components

HARDENING DIVISION

AUTOMOTIVECRANKSHAFTS DIVISION

Manufacture of crankshafts ready to install in automotive and industrial engines.

Lengths up to approx. 1000 mm Performance up to approx. 850 kW Speeds up to approx. 20 000 rpm

Our core competences:

Technological development, project and quality management and logistics.

All the necessary manufacturing processes, perfect surface treatment and mounting of auxiliary components ready for installation of the crankshaft.

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From prototype to series manufacture ... ... all on one site.

Development and production of induction hardening equipment.

Lengths up to approx. 1500 mm Cylinders up to 24 Engine types In-line engines V-engines (with or without split-pins) boxer engines


Individual and modular machine concepts.

Design and integration of hardening equip-ment in the customer‘s production line.

Consequent application of ALFING‘s harde-ning experience gained in our own crank-shaft production to customer‘s productions.

Fastest hardening process technology in the world.

Almost from the beginning of motoring, Karl Kessler was involved in the manufac-ture of crankshafts.

This is what ALFING‘s almost one hundred years of experience is based on.

And from where all our fields of activity and divisions have developed.

Crankshafts: That‘s what we know about



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LARGE CRANKSHAFTS DIVISION

Manufacture of large crankshafts ready for assembly.

Lengths up to approx. 8000 mm Swing diameter up to approx. 900 mm Performance up to approx. 12 000 kW Speeds up to approx. 3000 rpm


Technological development, project and quality management and logistics.

One-off and series production.

Forging and heat treatment of crankshafts.

Rough machining, surface treatment, finish machining, manufacture of accessories and crankshaft assembly.

Gensets Stationary or mobile units, for standby or continuous operation, diesel or gas engines

Marine Main drives, auxiliary drives, pri- mary high-speed ships‘ engines

The most important markets for large crankshafts from ALFING are as follows:

Vehicles Heavy duty construction equipment e.g. for quarries and mining, diesel lo- comotives, special-purpose vehicles

Machines Pumping stations, refrigerating units, bio-gas engines (for waste recycling & farming) as well as many specialised applications.

From project planning …… to crankshafts ready to install.

ALFING Competence

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SIMULTANEOUS ENGINEERING

Forging, rough machining and heat treat-ment (only for large crankshafts), surface treatment / hardening, finish machining and assembly ... all at a single site ... ALFING offers you the whole value-added chain.

ALFING COMPETENCE: More than „just crankshafts“

Within the scope of ‚Simultaneous Engi-neering‘ together we can help optimise your crankshafts from the point of view of performance, cost and design.

Needless to say we are experts in the whole logistics chain, process develop-ment, tool and jig design and of course the machining processes too:

Overall competence is our strength

OVERALL COMPETENCE is written large at ALFING and means: One partner ... from the customer require-ment, to process development, to delivery of the crankshafts ready to be installed. OVERALL COMPETENCE is also synonymous with: highly skilled personnel.

This is why ALFING places great emphasis on having well trained personnel through its own apprentice training workshops and systematic personnel development.

Customer drawing Specification,

Functional requirements

CAD-FEM- simulation

Material testing & optimisation

Prototype manufacture

Component testing: fatigue strength, torsion, bending

Process development for increased productivity

Finish machining & assembly

Washing & remain- ing dirt analysis



All ... ... under one roof

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MANUFACTURING PROCESS

Crankshaft production at ALFING using our own induction hardening machines

Preparation of drawings, optimisation, design

Die manufacture CAD/CAM

Different forging processes

Heat treatment

Material testing

Pre- and intermediate machiningSurface treatment

& hardeningFinish machining

& assembly

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ALFING Large Crankshafts

Since the early 1920s ALFING has been manufacturing large crankshafts to the highest and most innovative standard. We are the largest independent manufacturer of 1000 to 8000 mm long crankshafts in the world.

For large crankshafts we provide of the complete added-value chain in-house, from simultaneous engineering, component design, material procurement, forging through to delivery of the finished crankshaft ready to install.

The pillars of the division

We will transform your crankshaft designs into production manufac-turing documents together with your experts.

For this we use the latest 3D CAD/CAM systems.

ALFING can offer nearly all forging, heat treatment and ma-nufacturing technologies...... engineering know-how develo-ped through practical experience. We can provide the whole lo-gistics chain – from planning, material procurement and testing ... through to the certification approval and delivery of the fully assembled crankshaft.

The ALFING forge primarily pro-duces blanks for manufacturing crankshafts in-house. The necessary dies and tooling are developed and manufactured by ALFING.

Drop forging at ALFING:> Raw forging weights up to 2600 kg > Swing diameters up to 600 mm > Lengths up to 4200 mm

For crankshafts over 4200 mm ALFING uses Throw-by-throw forging: > Raw forging weights up to 13 000 kg > Swing diameter up to 1000 mm > Lengths up to 9000 mm

The challenge for the ALFING forge is to reduce the machining allo-wances, optimise the grain flow and improve the mechanical properties.

ENGINEERING, LOGISTICS

ALFING LARGE ENGINE CRANKSHAFTS: Worldwide leading potentials

FORGING SURFACE TREATMENT HARDENING

Our extensive experience in surface treatment, hardening and develop-ment of new processes are further competitive advantages which ALFING has to offer.

Bearing surfaces and fillet radii can be treated e.g. by> Nitriding> Stroke peening > Induction hardening using ALFING Hardening machinesto improve performance. This ALFING know-how provides your engine with much more power for the size available and greatly reduced wear.


LARGE CRANKSHAFTS

www.alfing.de

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From generating sets to ocean liners

MECHANICAL MANUFACTURE

We took the deliberate decision to carry out the complete process chain for manufacturing crankshafts in-house.

Thus, at all times, we can improve and optimise each individual process operation.

ALFING has ultra-modern manufac-turing facilities with CNC machines and a comprehensive quality management system for:> Crankshaft manufacture> Manufacture of accessories> Dynamic balancing> Automatic washing > Residual dirt analysis

Our production ends with delivery of the fully assembled and inspected crankshaft ready to be built into the engine.

From vision to reality

ALFING provides of nearly all possibilities in development and manufacture of large crankshafts to realise your requirements.

Product design and optimisation

> Materials for forgings and accessories > Forging design > Web contours > Bearing and fillet radii > Oil hole systems > Oil duct countersinks > Lightening holes > Various surface treatment processes > Counterweights (bolted on / forged) > Mounted / shrunk-on gears > Plugs for oil holes > Tolerances

Logistics for forgings, crankshafts and accessories

> Project management > Engineering > Simulations > Production planning > Material procurement > Die, jig and tool design > Quality planning > Process control > Quality management > Acceptance & Classification > Delivery of the finished crankshaft ready for installation

With crankshafts there is hardly anything which we haven‘t already made at least once. Thus we can offer you comprehen-sive support at every stage of development

of your crankshaft, e.g. during simultane-ous engineering projects where together with you we optimise, simulate and test the crankshaft for your engine.

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Engineering and logistics

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The ALFING drop forge aims to assure a high-grade quality, close tolerances and good grain flow of the forgings.

Modern CNC die-sinking machines linked to 3D CAD/CAM develop-ment systems assure efficient and high-quality die manufacture.

For the forging process, ALFING is equipped with counterblow ham-mers up to 63 metric tonnes, the final forging contour being achie-ved in a succession of heating and forging operations.

Drop forging at ALFING:> Forging weights up to 2600 kg > Swing diameters up to 600 mm > Lengths up to 4200 mm

In the throw-by-throw forging pro-cess the HfH (Hub-für-Hub) and TR (Tadeusz Rut) forging devices are used. The tools required for these processes are designed and ma-nufactured by ALFING.

In these forging processes only part of the forging spindle is hea-ted at a time. An initial axial upset-ting motion is then accompanied by a vertical offsetting motion to form the crank throw.

The focus of all ALFING forging processes is on the high precisi-on of the contour, to reduce the amount of subsequent machining.

Throw-by-throw forging at ALFING:> Forging weights up to 13 000 kg> Swing diameters up to 1000 mm > Lengths up to 9000 mm

DROP FORGING

ALFING LARGE ENGINE CRANKSHAFTS: Worldwide leading forging competence

THROW-BY-THROW-FORGING

HEAT TREATMENT

Heating, quenching and tempe-ring: these processes are used to obtain exactly the strength values required.

The temperatures and times re-quired for these processes are determined by ALFING engineers and then tested and documented in the materials laboratory.

We have up-to-date heat treat-ment equipment to perform the heat treatment processes:> Heating furnaces> Quenching baths with oil or emulsion > Laboratories for testing the mechanical properties

Naturally we also provide our comprehensive expertise to our customers.

The large forging competence

ALFING has comprehensive experience in throw-by-throw forging, drop forging, heat treatment and forging finishing.

The quality of the crankshaft depends on the quality of the crankshaft forging. Thus we have built up our forging know-how over seven decades, with the main focus on forgings for manufacturing ALFING crankshafts.

Forging design and optimisation, design and manufacture of dies and jigs, materi-al procurement, the forging process itself, heat treatment and forging finishing: the whole value-added chain at a single site and a single partner – ALFING Forge.

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LARGE CRANKSHAFTS

www.alfing.deFORGING FINISHING

Forging: From billet to finished forging

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Prior to the forging being machined into a crankshaft, the forging under-goes the ALFING finishing process:> Sandblasting to remove forging scale and dirt from the forging> Visual inspection> Fluorescent crack detection> Ultrasonic inspection> Material testing as specified by the customer, to determine and docu- ment the mechanical and technological properties> Marking of the forgings to assure complete traceability, both inter- nally and externally. For this purpose each forging is allocated a unique serial number.

Via the serial number we can retra-ce each operation which was car-ried out prior to the dispatch of the finished, ready-to-install crankshaft.

Good ... better ... ALFING surface treatment

Crankshafts are functional components which have a key influence on the efficiency of the engine.

Often, through ALFING surface treatment, considerably more power can be obtained from an engine of a particular size ...

... with greatly reduced wear.

We offer the following processes for surface treatment:

> Nitriding

> Stroke peening

> Induction hardening

These processes, some of them developed in-house, have been refined in industrial series production in ALFING‘s own production.

This is especially true for induction hardening using hardening machines produced by our har-dening division. Benefit from this ALFING expertise.

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Diagram - Bending fatigue test results


LARGE CRANKSHAFTS

www.alfing.de

This leads to:BETTER PERFORMANCE

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Manufacturing competence on site

At ALFING our expertise is not only confined to applying our knowledge to well known production processes.

For ALFING manufacturing competence also means: development and implementation of new processes and the production of purpose-built machines.

Yet another unique selling point in ALFING‘s favour when it comes to reducing the manufacturing costs of your crankshafts.

ALFING LARGE ENGINE CRANKSHAFTS: Leading technology worldwide

PRE- & INTERMEDIATE MACHINING

ASSEMBLYSURFACE-TREATMENT

GRINDING FINISHING

> Cost-effective rough machining through external and internal milling with milling diameters of up to 1650 mm > State-of-the-art CNC turn milling centres with over 100 tools in the magazine> Manufacture of radii with axial & radial undercuts

> Nitriding > Stroke peening> Induction hardening

> CNC grinding with CNC dressers> Grinding of long tapers with a single (!) grinding wheel in a single (!) setup > Automatic band finishing

> Mounting of counterweights > Mounting of toothed gears > Tight fitting of the caps to the oil duct system through rolling> Dynamic balancing Balancing up to approx. 13 tonnes and swing diameters up to 1200 mm

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Das bringt:MEHRLEISTUNG




LARGE CRANKSHAFTS

www.alfing.de

> Washing > Final inspection > Certification, in some cases carried out by ourselves on be- half of well-renowned classification societies > Conservation and packing in air- conditioned clean rooms

WASHING INSPECTION

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Perfection in precision

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No compromises ... … the basis of our success

Compliance with the standards

ISO/TS 16949:2002 and

DIN EN ISO 14001:2004

has for many years assured that ALFING satisfies the highest quality and environ-mental demands.

Furthermore our in-house testing and laboratory technology satisfy the most stringent customer requirements.

All necessary information can be engra-ved on the crankshaft at the customer‘s request, e.g. in dot-matrix code.

Our multi-layer quality system has proved its value in practice:

> Quality planning

> First part acceptance after each operation

> Constant self-testing by the operator

> Quality assurance based on the inspection plan

> Final inspection of each individual crankshaft

„Totale“Kurbelwellen- kompetenzThe world renowned ALFING competence is continually being further expanded through our „Basic Development“.

For this ALFING developers have an extensive array of state-of-the-art laboratory, measuring and test equipment at their disposal, lea-ding to patents which protect our know-how worldwide:

So that you, too, can benefit from these developments, we offer you our „Competence“ as a service for crankshaft opti-misation.

Where necessary we can even develop special-purpose ma-chines to implement the newly developed process in practice.

Environmental protection at ALFING is an integral part of management and is lived out in practice. We demand environmental awareness and commitment from all of our employees. To assure optimal environmental protection, our procedures are certified at regular inter-vals by internal and external audits.

ALFING‘s environmental policy commits the company to compliance with all environ-mental laws and regulations.

By proactively taking into account the ef-fects on the environment, ALFING aims to avoid emissions and make economical use of energy resources.

„Totale“Ku rbelwellenkompetenz> CAD-FEM simulation of crankshaft

> Development of processes to increase crankshaft performance within the given available space

> Material testing

> Trials for component strength and component optimisation

> Balancing analyses on the CAD model

> etc.

„Total“ crankshaft competence


LARGE CRANKSHAFTS

www.alfing.de

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Quality inblack and white

Zertifizierung bedeutet: Qualität und Sicherheit

We could write a lot about the quality of our crankshafts.

However, this quality is confirmed through certification by national and in-ternational classification and certification societies ...

... and they take quality seriously:

Technology assures … … our quality

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Competence, technology, quality

Solid tradition, modern management, decades of experience+ Know-how about crankshafts + Understanding of how engines are designed and work + Drop forging and throw-by-throw forging + Competence in crankshaft manufacture + Modern manufacturing technology + Perfect quality management + Comprehensive project planning + Know-how in materials technology + Increased engine performance through surface treatment + Complete testing, measurement and laboratory technology + Reliable processes, precise logistics + Know-how about induction and hardening technology + Modular components for hardening machines + Services, hotline & support – around the clock + On-going investment in production facilities + Continuous further education and training ______________________________________________

= Leading the field

This is what ALFING offers you

We incorporate the solutions to these challenges – in the form of research, development, education & training, technology and productivity ...

... into our daily work.

What‘s in it for you?

Maximum performance, quality and added value.

The high demands of our customers keep us on our toes.

This is where our leadership in innovati-on and quality results from.

That is how it should be ... ... because it is to your advantage.


LARGE CRANKSHAFTS

www.alfing.de

Win-Win ... with crankshafts from ALFING

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MaschinenfabrikALFING KESSLER GmbH

Large Crankshafts Division

Auguste-Kessler-Strasse 2073433 Aalen / Germany

Tel. +49 (0)7361 - 501-1340Fax +49 (0)7361 - 501-4416

[email protected]

alfing kessler gmbh large crankshafts alfing … · maschinenfabrik alfing kessler gmbh large...

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