Crankshafts for large engines

The most diverse applications, demanding crankshaft designs - with the interaction of our state-of-the-art machinery, innovative technologies and our qualified employees, we can realise any requirement. From the raw material to the ready-to-install crankshaft - everything from a single source.

Ingo Gerneth MAFA Alfing — **Ingo Gerneth**

Email: ingo.gerneth@spam-protected.tld.demafa.alfing.de<br/> Phone: +49 (0) 7361 / 501 1340

Intro with contact person

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Part 1

Engineering

All parameters of the design are defined and optimized together with the customer: Materials, web profiles, radii, oil drilling systems, surface treatment and counterweights etc. Our specialists accompany all sub-processes from planning to material procurement, laboratory tests and simulations to certification and delivery of the ready-to-install components. State of the art systems enable direct data exchange with customer systems. The seamless interaction of all processes ensures maximum efficiency.

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Forge

In principle, we forge forged parts for large crankshafts in-house. In this way, we can ensure and constantly optimise quality at all times. All dies and devices are designed and manufactured in-house. Depending on the length, the raw parts are forged in a die or formed in stroke-by-stroke devices with 3,500 t presses. In the subsequent heat treatment, we adjust the material properties required precisely. In this way, the raw parts are perfectly prepared for the subsequent machining work.

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Mechanical processing

All mechanical production processes are developed and carried out in-house. Whether internal or external milling, turning, deep hole drilling, gear cutting, deburring, grinding, balancing or finishing: Each process step is recorded online and continuously optimized. We have state-of-the-art CNC-controlled machinery and seamless quality management. This also accompanies the processes of assembly, dynamic balancing, automatic washing with residual dirt analysis and crankshaft certification.

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Surface treatment

One of our core competencies is the hardening of crankshafts. The surface treatment by nitriding, impact hardening or induction hardening increases fatigue strength, allows higher engine performance and reduces wear. The Hardening Machines division has developed from this special know-how: Development and manufacture of induction hardening machines for our own crankshaft production and for customers worldwide.

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large crankshaft assembly finishing alfing kessler

Finishing and assembly

Many accessories, manufacturing processes and perfect final assembly are required before the crankshaft is ready for installation.
Every single crankshaft is brought to perfection in the finishing process. In addition to automated processing, manual work steps are carried out by qualified employees with many years of practical experience. The quality and process reliability are guaranteed in the subsequent final inspection. The crankshafts are then cleaned in fully automatic washing lines, checked visually and finally preserved and packed in air-conditioned clean rooms.

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