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DIESEL INJECTION TECHNOLOGY

With the first common rail direct injector production vehicle in 1997, a new dimension in high pressures began, along with increased accuracies in the components of the pump, valve and injector system assemblies. Bahmüller has decisively contributed to this evolution in the serial production of diesel technology. The components became smaller, but the grinding tasks became increasingly more complex. Bahmüller also decisively advanced the combination of internal and external grinding on one part, by which more and more spindles were required in one clamping, into complex machining and brought unrivaled clamping and drive systems to the market, such as hydrostatically mounted middle clamping, in which the front and rear side of the part are ground simultaneously. Ever-shortening cycle times and the associated shortening of part changing times led Bahmüller to become a loader manufacturer, since this kind of flexible technology was not on the market.

HIGH PRESSURE PUMP (COMMON RAIL)

HIGH PRESSURE SEATING (MIDDLE CLAMPING)


Specific components and process features:

  • axes designed wear-free through hydrostatics
  • best acceleration values through linear motor drives
  • highest quality through hydrostatic linear axes without reversal backlash
  • wear-free work piece headstock through hydrostatic bearing
  • specifically configured dimensional check station integrated in processing machine
  • optimized cycle time through coordinated oversizes
  • simultaneous engineering through independent TEC center
  • specially configured post-process measurement technology
  • optimized quality through simultaneous machining from both sides
  • specially configured grinding mandrel with a length of approx. 75 mm protruding out of mandrel fixture (incl. abrasive coating)
  • start-up oriented, machine-internal automation that is operated ahead of time, manually loaded





This allows us to achieve:


  • roundness on ground seat <0.6 μm
  • concentricity of seat to bore simultaneously ground from the other side < 1.5 μm
  • optimized seat surface through pre-grinding and finish-grinding Pt<0.85 μm

ROLLER GUIDE

Specific components and process features:

  • double diaphragm chuck
  • highest quality through hydrostatic work piece headstock
  • integrated dimensional check on 3 levels
  • automatic WSS swivel axis = automatic cylinder correction
  • in-process oversize control


This allows us to achieve:

  • parallelism of clamping diameter to internal diameter < 3µm
  • roundness bore < 0.3μm
  • surface quality Ra < 0.03µm
  • profile deviation < 0.3µm
  • diameter fluctuation < 4µm

NOZZLE

NOZZLE NEEDLE (SEAT & MATCH GRINDING)


Specific components and process features:


  • CBN grinding wheel
  • 2 diameter in-process measurement heads
  • piezo tailstock
  • pre-measurement station
  • dimensional check station





This allows us to achieve:

  • cycle times < 15s
  • straightness < 0.3µm
  • guide diameter roughnesses Ra < 0.06µm
  • gap dimension deviation <1µm
  • roundnesses < 0.3µm

NOZZLE NEEDLE (IN ROLLER ASSEMBLY)

Specific components and process features:


  • roller assembly
  • hydrostatic axes
  • external grinding wheel with CBN
  • rotating dressing


This allows us to achieve:


  • Seat angle +/- 0.1° cmk>2
  • roundness 1.2 µm cmk>2
  • straightness 0.8 µm cmk>2s
  • course to receptacle diameters 2µm cmk>2
  • Rz 1.3 / Pt 1.4 cmk>2
  • grinding time 6.5 sec.

NOZZLE BODY INTERNAL GRINDING

Specific components and process features:


  • 2 station Twinner machine (2 grinding units on one machine base)
  • integrated dimensional check station on 4 levels for shape and diameter correction
  • adaptive grinding = oscillation evaluation for spark out time reduction
  • envelope curve monitoring for recognition of tool breakage


This allows us to achieve:


  • halving of cycle time with proportionally low investment
  • directed parallelism < 1µm
  • cycle time modification or optimization approx. 3 sec.
  • waste elimination due to irregularities

GEAR WHEEL FEED PUMP

GEAR WHEEL (BORE GRINDING AND SURFACE GRINDING)


Specific components and process features:


  • hydrostatic axes
  • grinding spindle 1 for bore
  • grinding spindle 2 for flat side
  • rotating dressing
  • dimensional check station for bore for 100% verification
  • special clamping device for clamping in tooth flanks
  • Twinner setup for double yield





This allows us to achieve:

  • tooth flank working variation 0.020mm cmk 1.67
  • bore cylindricity 0.010mm cmk 1.67
  • bore RZ4 cmk 1.67
  • course plane surface to bore 0.010µm cmk>1.67
  • machine cycle time 16 sec.

INJECTOR VALVE COMPONENTS

LONG DEFLECTION-CRITICAL PARTS


Specific components and process features:


  • roller assembly
  • hydrostatic axes
  • external grinding wheel with CBN
  • rotating dressing





This allows us to achieve:


  • total length 100mm +/-0.02 cmk 1.67
  • concentricity to the receptacle diameters 0.02mm cmk 1.67
  • diameter -0.005mm cmk 1.67
  • area shape on the planar side (radius) 0.004mm cmk 1.67
  • cycle time incl. automatic loading + dressing: 8 sec.

VALVE BODY

Specific components and process features:


  • insert 250,000 1/min frequency spindle to 1mm bore grinding
  • planar finishing spindle for preventing further clamping
  • dimensional check station for longitudinal and diameter verification
  • axial chuck with radial centering compensation for clamping non-concentric bores


This allows us to achieve:


  • coaxiality, seat to bore < 0.7µm
  • plane surface Ra < 0.05µm
  • plane flatness < 2 μm
  • right angularity < 2µm

WE ARE LOOKING FORWARD FOR YOUR CALL


Our head office will be glad to advise you.

phone +49-(0)7181-809-0
fax +49-(0)7181-809-234
e-Mail info@bahmueller.de


You will find your personal contact on the different departments under the rubric service.

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