Rolling Forged Camshaft
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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 rightangle 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.
Rolling Forge Machine Area: 6500 m2 Machine quantity: 60 machines,3 forge lines Employees: 150
Shifts: 3
Production: 1800,000 pieces a year
H1200 rolling forge machine
Rolling forge
Rolling forge raw camshaft
Rolling Forge Workshop
Rolling forge process material checking
normalizing
cutting
straightening &detecting
induction heating
raw bar of camshaft
rolling forge
Finished machine Area:8000 m2 3 produce lines Employees: 120 Shifts: 3 Production: 500,000 pieces a year
INSTRUMENT ADCOLE MODEL-911 Made in USA 2002 Cam grinding machine JUNKER JUN5000/10 Made in Germany 2002
Cam grinding machine SCHAUDT CF-61 Made in Germany 2002
Machining Workshop Overlooking
camshaft machining process Raw bar of camshaft
center drilling& turning
lobe milling
rough grinding
induction hardening& tempering
Finished grinding
Crack detecting
Checking
marking& packing
Checking machine
Hardness measurement HRC,HB,HV Future FV700,Japan
Metallography Microscope Electronic strength instrument Olympus PMG3 Japan Made in China
Checking Machine
3D-Coordinate measuring machine
Instrument for camshafts
Made in china
ADCOLE MODEL-911 Made in USA
Comparison with the traditional machining Raw’s Size of Weight Example Steyr 6 cyl. camshaft
Rolling forge Bar Results
Caterpillar 6 cyl.
camshaft
lay-off
(kg)
turning Time
Ф65×715
18.63
16.5min. The mechanical
Ф65×985
25.64
Material Save 27.3%
24.5min. efficiency improve 48%
Ф65×615
15.89
12min.
Bar
φ65×876
22.81
19min.
Results
Material Save 30.3%
Rolling forge
Mechanical character
efficiency improve 58%
character improve 25% ; Metallograph refine than the bar.
Sample Cutting
Steel bar ： φ65×715
Rolling forge
Raw camshaft φ65×985
Turning
Semi-finished camshaft φ61.8×980
Steyr 6 cyl. Camshaft
Sample Cutting
Steel bar ： φ65×615
Rolling forge
Raw camshaft φ65×876
Turning
Semi-finished camshaft φ62.2×872
Caterpillar 6 cyl. Camshaft
Different state camshafts Rolling forged Turned Lobe milled Lobe grinded Material : SAE1080 CF53 45
20Cr
…
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 rightangle 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.
Rolling Forge Machine Area: 6500 m2 Machine quantity: 60 machines,3 forge lines Employees: 150
Shifts: 3
Production: 1800,000 pieces a year
H1200 rolling forge machine
Rolling forge
Rolling forge raw camshaft
Rolling Forge Workshop
Rolling forge process material checking
normalizing
cutting
straightening &detecting
induction heating
raw bar of camshaft
rolling forge
Finished machine Area:8000 m2 3 produce lines Employees: 120 Shifts: 3 Production: 500,000 pieces a year
INSTRUMENT ADCOLE MODEL-911 Made in USA 2002 Cam grinding machine JUNKER JUN5000/10 Made in Germany 2002
Cam grinding machine SCHAUDT CF-61 Made in Germany 2002
Machining Workshop Overlooking
camshaft machining process Raw bar of camshaft
center drilling& turning
lobe milling
rough grinding
induction hardening& tempering
Finished grinding
Crack detecting
Checking
marking& packing
Checking machine
Hardness measurement HRC,HB,HV Future FV700,Japan
Metallography Microscope Electronic strength instrument Olympus PMG3 Japan Made in China
Checking Machine
3D-Coordinate measuring machine
Instrument for camshafts
Made in china
ADCOLE MODEL-911 Made in USA
Comparison with the traditional machining Raw’s Size of Weight Example Steyr 6 cyl. camshaft
Rolling forge Bar Results
Caterpillar 6 cyl.
camshaft
lay-off
(kg)
turning Time
Ф65×715
18.63
16.5min. The mechanical
Ф65×985
25.64
Material Save 27.3%
24.5min. efficiency improve 48%
Ф65×615
15.89
12min.
Bar
φ65×876
22.81
19min.
Results
Material Save 30.3%
Rolling forge
Mechanical character
efficiency improve 58%
character improve 25% ; Metallograph refine than the bar.
Sample Cutting
Steel bar ： φ65×715
Rolling forge
Raw camshaft φ65×985
Turning
Semi-finished camshaft φ61.8×980
Steyr 6 cyl. Camshaft
Sample Cutting
Steel bar ： φ65×615
Rolling forge
Raw camshaft φ65×876
Turning
Semi-finished camshaft φ62.2×872
Caterpillar 6 cyl. Camshaft
Different state camshafts Rolling forged Turned Lobe milled Lobe grinded Material : SAE1080 CF53 45
20Cr
…
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