About the Client

A leading joint venture manufacturer of forged components, primarily serving the automotive sector with complex and critical parts such as crankshafts. Known for their scale, quality, and delivery standards, the client sought a partner who could match their speed and precision expectations.

The Problem They Faced / Challenges

• The client required a machining solution for crankshaft oil hole drilling that could meet extremely tight tolerances with repeatable accuracy, while handling high production volumes.

• Holes in crankshaft are almost always at compound angles with each hole being at a different orientation from the other in the same crankshaft. This makes approaching the holes on a machining center difficult, there-by increasing the tool lengths & making the process impractical on a machining center.
  

Key challenges included:

• Cycle time limitation of just 4 minutes per machine
• Multi-operation drilling requirements (spot facing, pilot drilling, deep hole drilling, chamfering)
• Accurate positioning of oil holes across multiple reference points (within ±0.2 mm)
• Demand for zero deviation during continuous, high-volume operation

The Solution

BFW delivered a complete machining solution by supplying our Horizontal Machining Centers –MCR (Moving Column Ram type) with following features.

• Optionally, fully integrated with Gantry Automation to ensure efficient loading/unloading.

• Custom fixturing for precise oil hole drilling (We can offer for single cylinder crankshaft to 4 cylinder crankshaft).

• Integration of 4th & 5th axis rotary tables to manage complex geometry.

Advantages of the MCR Machine:

• Zaxis on RAM helps take the spindle very close to the component, even when the component is oriented at a compound angle.This reduces the tool length considerably which results in better cutting parameters & improve tool life.
• Central chip conveying system right below the cutting zone helps in most efficient chip removal from the cutting zone.
• Feasibility of using Minimum Quantity Lubrication (MQL) system with the machine.
• MQL has the following advantages

– Cools the tool tip better than regular coolant. This helps in operating drills at nearly 8 times the feed rate of conventional deep hole drilling process.

– Higher feed rates ensures small, well-burnt chips which take away the heat from the component and are also easy to handle.

– Chips generated are near-dry & clean, there-by-making them easier to handle & dispose.

– There is no need for high pressure coolant. Only minimal coolant for flushing the chips from the machining zone is all that’s needed.

– MQL is environmentally friendly, clean & green.

Results:

• 100% tolerance achieved for critical dimensions on oil hole positions

• Cp values of 1.67 achieved for oil hole diameters — exceeding the required 1.33

• Smooth ramp-up with no major tuning required post-installation
• Seamless coordination between machining centers and automation ensured minimal downtime

Happy Client

By partnering with BFW, the client achieved zero compromise in performance, precision, or productivity. The complete solution aligned with their lean manufacturing goals, ensuring a reliable and scalable operation. BFW’s proactive collaboration from planning to execution helped the client stay ahead in a competitive, quality-driven market.