What does a turbocharger do?
The task of the turbocharger is to supply compressed fresh or intake air to the engine with the help of the otherwise lost exhaust energy. This increases engine performance and efficiency compared to engines without a turbocharger.At first glance, this consists of two sides: The turbine side, which is driven by the discharged hot exhaust gases, and the compressor side, where fresh air is compressed. Exhaust gases and fresh air are fed in and out via the distinctive, screw-like and extremely heat-resistant housings. The approximately 250° Celsius on the compressor side is countered by around 1000° Celsius on the turbine side. An internal combustion engine reaches speeds of 6000 to 7000 revolutions per minute in the upper power level. These seem almost modest compared to the up to 400 000 revolutions per minute achieved by modern turbochargers.
Know-how in clamping technology
Turbochargers are highly stressed components and must be manufactured with corresponding resistance, but also with high precision due to the high temperature load and the enormous speeds.
EMUGE-FRANKEN's clamping technology department has designed several clamping concepts for different machining processes in the manufacture of turbochargers.In this article, we take a closer look at a clamping device used in the machining of turbocharger housings.
Clamping concept for higher productivity
The developed clamping concept and the implemented design differ greatly from conventional clamping systems. The special shape and the use of clamping fingers - in addition to clamping hooks, typical for a high-precision diaphragm clamping device from EMUGE-FRANKEN - are striking. The reason and benefit for this: The open design optimises chip removal during machining. In addition, the distinctive clamping fingers ensure defined face clamping and enable the absorption of high cutting forces. By the way, this does not contradict accuracy: despite demanding machining and high forces, the clamping device centres the workpiece without deforming it - with µm accuracy and repeatability. This process is also supported by the alignability in all three axes.The concept allows the machining tools to be fed from five sides without having to reclamp the workpiece. In addition, special materials ensure complete corrosion resistance, which in turn contributes to the longevity of the clamping device.
Our ideas - your added value
The clamping device offers our customer a lot of advantages: First and foremost is higher productivity, which can be expressed in figures: up to 25 percent more parts can be produced in the same time, of course with the same quality. Also positive time factors and process accelerators: exchanged clamping elements can be used immediately without realignment, the clamping device has a quick-change connector.
In summary: The clamping concept is innovative and reliable, the clamping device highly accurate and low-maintenance.Ask our contact person if you would like to know more about our clamping concepts for machining turbocharger components. We are ready!