Fracture Splitting of Bearing Caps
Uncompromising Economical
ALFING on the forefront of technology
ALFING has pioneered the development of the fracture splitting process for bearing caps on motor blocks. As early as 2003, the first worldwide, fully automatic cracking machine for a 6 cylinder truck engine was delivered. The cracking process provides extensive cost savings, because the rough and finish machining of the joint faces is eliminated.
Layout of a Bearing Cap Cracking Machine
Highlights
- Extensive cost savings when compared to the conventional manufacturing process because the machining of the joint face on the cap and motor block is eliminated
- Reduced logistic costs because the motor blocks and bearing caps are not shipped separately
- Accepting high load force due to the structure of the cracked surface
- Optimum assembly behavior
- Possible semi automatic or fully automatic production
Laser - Station
Two stress risers at each bearing cap are produced in the laser station with the help of a laser lance.
The stress risers are produced sequentially. The laser lance travels through the crank bore and produces the stress riser on one side of the bearing cap during the instroke and on the opposite side during the return stroke. The installed high tech laser guarantees consistent stress risers and therefore, excellent fracturing results.
Fracture Split Station
In the fracture split station, the cracking is performed by a cracking mandrel.
The cracking mandrel travels along the crank bore of the motor block. The bearing caps are cracked sequentially. The bearing caps are hydraulically supported during the fracturing process, which provides an even crack on both sides.
Load/Unload
Extreme flexibility
The required cycle time determines the degree of automation for the system. The equipment can be easily integrated into a production system with the use of conveyors, gantries or robots. The bolt assembly of the bearing caps can be performed manually or in automatic mode. Additional options like gauging or marking can be easily integrated.
