THE TURNKEY SOLUTION FOR MACHINING NEW
GENERATIONS OF TURBOCHARGERS

Productivity PLUS! A highly efficient solution in turbocharger manufacturing from STAMA Maschinenfabrik GmbH and KOMET GROUP GmbH

A time saving of up to 67%.
Machining time reduced by up to 25%.

The combination of the STAMA MT 838 TWIN milling-turning centre and KOMET® machining optimisation with a special  KomTronic®  U-axis tool is setting new standards. A time saving of up to 67% is achieved for V-belt machining alone. This is mainly the result of interpolation grooving and turning, which replaces the circular milling process which was originally used, and the result of the use of  KOMET®  U-axis systems.

The result: The time required for the entire machining process for the component is reduced by 25%. In addition to drastically reduced tool costs.

Benefits for you:

  • Significant reduction in machining process by 25%
  • Increase in ultra-precise machining
  • Tool life increased by several degrees
  • Fewer tools required
  • Integrated assistance and monitoring system
  • A high degree of automation designed for series production
  • Increase in long-term quality of turbochargers

 

Flyer turbocharger

Turbocharger manufacturing

Productivity Plus! A highly efficient solution in turbocharger manufacturing from STAMA Maschinenfabrik GmbH and KOMET GROUP GmbH.

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Requirements for turbocharger manufacturing:

Relating to the material

  • Extremely high requirements relating to thermomechanical properties, high heat resistance – use in temperatures of up to 1100 °C for petrol engines
  • Use of high-alloy, high-temperature-resistant materials with a high nickel and chrome content
  • Extremely low thermal conductivity (Heat is directed into the machining tool)
  • Strong tendency towards strain hardening
  • Highly abrasive cast skin, edge zone hardness up to 450 HV 0.5
  • Austenitic matrix with chromium carbides requires high cutting forces, which result in a relatively short tool life
  • In short, abrasive and difficult to cut

 

Relating to machining

  • High requirements relating to form and position tolerances
  • Automated series production
  • Reduction of costs per piece and the machining time

INNOVATIVE SOLUTIONS FOR TURBOCHARGER MANUFACTURING

The solution on the machine side

  • STAMA milling-turning centre with TWIN technology 2+4 solution
  • Complete machining on a single-station millingturning centre
  • All of the important machining steps can be carried out with the workpiece clamped in a single position

Machining strategy

  • Rotationally symmetrical machining with highly asymmetric component
  • Use of freely programmable  KOMET  KomTronic®  U-axis systems enables any type of contour machining and turning on parts which are not rotationally symmetrical. Through the combined use of customised snap-on tools and optimally selected indexable inserts
  • Machining contours in bores as well as internal and external machining results in a significant reduction in production times, better surface quality, and improved dimensional accuracy
  • Fewer tools required
  • Use of 3D-printed special tools with innovative coolant channels adapted to the process

KOMET®  arbor face-milling cutter for machining of turbo chargers Ø 50 – 125 mm
With double-sided octagonal indexable inserts with 16 usable cutting edges.

Benefits for you:

  • Robust design, stable and secure position in the basic body
  • Special cutting material suitable for the toughest thermomechanical requirements
  • Defined, stable cutting edge guidance
  • Maximum productivity, process reliability and cost-efficiency guaranteed

Pre-machining of V-belt outer diameter –  KOMET®  interpolation grooving and turning tool

Benefits for you:

  • Extremely stable tool design
  • Special adaptation of the cutting edge geometry to the machining process with regard to machining time and stability
  • Internal coolant supply directly to the tool's cutting edge



Finish machining of V-belt outer diameter –  KOMET  KomTronic®  U-axis systems
With 3D-printed snap-on tool and indexable inserts in special designs, with three cutting edges with ground recess geometry and flute.

Benefits for you:

  • Considerably higher cutting values than with conventional machining
  • Integrated position measuring system
  • Short, stable tool design thanks to optimal compact connection

Finish machining of counter bearing conical hole –  KOMET  KomTronic®  U-axis systems
With stepped snap-on tool with four indexable inserts.

Benefits for you:

  • Complete finish machining with a single tool
  • Enables maximum precision to be achieved
  • 99% use of standard indexable inserts
  • Direct coolant supply to the individual cutting edges
  • Integrated position measuring system
  • Short, stable tool design thanks to optimal compact connection