Turbo housing with exhaust manifold

 Heat-resistant steel casting

The manufacture of exhaust manifolds and turbo housings on a machining centre presents particular challenges for tools and machines alike.

The machining process requires the highest levels of precision and wear resistance. The crucial machining operations for this process are: Milling the exhaust manifold surfaces and the relief grooves, counterboring the main bore and V-flange machining. In order to ensure a long tool life and stable processes, the focus is on designing the tools for maximum stability.


Rough milling of the exhaust manifold surface

Solution:

Walter heptagon milling cutter with a double-sided indexable insert

  • ► 14 cutting edges
  • ► The latest TigerĀ·tecĀ® Gold cutting tool material
  • ► Shim to protect the insert seat
  • ►  Suitable for machining chrome-nickel steels

Machining the side of the turbine

Solution:

Walter combination tool for drilling

  • ► Drilling the main bore
  • ► Simultaneously: Forming the V-flange
  • ► Small number of tools in the magazine

V-flange: Interpolation turning

Solution:

Walter interpolation tool

  • ► Two effective cutting edges for roughing operations
  • ► Cost-optimised indexable insert with 3 cutting edges
  • ► Cartridge system for double spindle machines

Finishing V-flange and inner contours

Solution:

Walter CaptoTM turning tool with two indexable inserts

  • ►  Finish machining of V-flange and inner contours with just one tool
  • ►  Stable insert on chrome-nickel steels, adapted indexable insert geometry