Improving the Quality of Powertrain Components

Engis Single-Pass Bore Finishing for Rocker Arms

Engis is a global partner in the quest to continuously improve the quality of power train components.   We have worked closely with manufacturers in the Americas, Asia and Europe to improve the quality of fit and finish on a wide variety of components, while at the same time reducing cycle times, rejects and lowering overall costs.

We work with Tier I and Tier II automotive manufacturers, as well as companies involved in the production of diesel and marine engines.  Our expertise in Bore Finishing/Honing, Grinding, and Lapping has produced many success stories and satisfied customers.  Also, our global sales and service organization guarantees superior after-the-sale application and service support.

Some of our most successful applications include:

• Blocks
  • DiaForZ® products for foundry cleaning rooms
  • Abrasive machining of bimetal decks for marine engines using the Engis Electromill™

• Crankshaft – Abrasive machining of raw casting
  
  
• Connecting Rods – Precision finishing of the bushing
  
  
• Fuel Injectors
  • The lapping of the fuel injector tips and nozzles
  • Precision finishing of the seat
  • Single-pass honing of the injectors

• Piston Rings – Grinding of the casting from solid and gapping
  
  
• Rocker Arms – Precision single-pass honing
  
  
• Turbo Chargers – Single-pass bore finishing of the housing

CASE STUDY - CONNECTING RODS
Challenge:  Inconsistent bore geometry High down-time High perishable tool cost Engis Advantage: Improved quality: Cpk >2 Improved bore roundness to better than 5um for the crank bore and 3um for pin bore Improved "Bend and Twist" Production Rate: 300 parts per hour Total perishable tooling cost for finishing both bores is roughly $0.03. Quick change-over between part types Pin and crank bores finished together in the same machine	Material:  Crank Bore Forged Steel / Pin Bore - Bronze Bushing
CASE STUDY - ELECTROMILL FOR ENGINE BLOCKS
A major manufacturer of marine engines faced serious challenges when milling bi‐metal engine blocks. They were unable to achieve the desired flatness, parallelism and finish requirements which resulted in an unacceptable level of rejected components and reworks.  The Engis Electromill system improved the process considerably, achieving a finish of 40μ Ra and flatness  of 60μ Ry. This resulted in better quality blocks with  virtually no rejects or rework.   The savings to the customer was substantial!
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