Turbo Housing

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 Tiger·tec® 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