In the construction of large-volume engines for shipping and the energy sector, MAN Energy Solutions holds a leading position worldwide. However, what must function smoothly on a large scale requires precise and reliable solutions in detail. For example, in the production of cast iron bearing blocks. However, the tools used until now were too inaccurate. A solution was finally provided by an innovation from ISCAR. The new three-edged interchangeable head drills LOGIQ3CHAM achieve top results and significantly improve productivity at MAN.
MAN Energy Solutions employs 14,000 people worldwide at 120 locations. The headquarters and largest production site is in Augsburg with 4,000 employees. Here, large four-stroke engines are produced for ships and stationary applications such as power generation. The development of climate-neutral solutions for customers from industrial production, energy, and maritime sectors is a central corporate goal.
37 years after its founding in 1840, industrial history was made in Augsburg: Engineer Rudolf Diesel built the world's first engine named after him in a laboratory of the Augsburg machine factory, now MAN. The largest engine produced there today has a power output of 19 megawatts and weighs 240 tons. In addition to the development, production, licensing, and distribution of large-volume four-stroke diesel and gas engines as well as turbochargers for ships, heating, cooling, and electrical systems, MAN Energy Solutions from Augsburg also manages the global business development of future solutions such as hydrogen technology.
A success factor is the high manufacturing depth implemented at the site. The entire engine production is represented in the plant – from the foundry to the finished engine.
Room for improvement in precision
Among the internal suppliers is the cubic component manufacturing with 30 employees. Here, 150 different components weighing between five and 300 kilograms are produced on six machines, including cast iron bearing blocks for the cylinder head control. 'To meet the high quality requirements, we need top-notch tools for machining,' explains Lukas Bachhuber, segment manager at MAN Energy Solutions.
However, problems arose when introducing screw holes. Drilling must be done from both sides, and the previously used two-edged interchangeable head system did not meet the requirements. 'The tool was too inaccurate. The holes must meet exactly. However, there were always deviations. Despite pre-centering, we did not achieve satisfactory results,' explains Lukas Bachhuber.
His colleague Alexander Baier, Tooling Technologies, adds: 'We have been intensively searching for a tool with very good performance' and explains why the long-standing contacts with ISCAR provided a solution approach. Dirk Moosreiner, application technology and consulting, and Detlef Ossadnik, consulting and sales, both from ISCAR, presented the new three-edged interchangeable head drilling system LOGIQ3CHAM.
LOGIQ3CHAM provides relief
Compared to conventional drilling tools with two edges, this allows feed rates that are up to 100 percent higher, significantly increasing productivity. The drill head clamping system is easy and safe to handle and, unlike conventional clamping systems, does not require any additional spare parts. 'This results in minimal setup times for drill head changes even in the machine,' explains Florian Weiß, Product Specialist Drilling at ISCAR.
The radial and axial clamping force is generated exclusively in the dovetail-like fit. 'It offers very high process reliability even with irregular cutting forces in combination with the large contact surfaces,' adds ISCAR Regional Sales Manager Uli Köhler.
ISCAR designed the drill head center or the remaining cross-cut with the three tapering cutting edges for good centering capability with as high stability as possible. This results in low axial forces and torque values during the initial drilling as well as very good self-centering capability. The LOGIQ3CHAM uses the PVD-TiAIN-coated cutting material IC908, which is highly wear-resistant and allows for long tool life.
All drill body variants have an internal coolant supply to each cutting edge as well as large, polished chip chambers that improve chip flow through variable spiral angles.
'After the presentation of the new tool, we conducted tests under practical conditions with our project partners,' explains Detlef Ossadnik. 'We quickly found that LOGIQ3CHAM runs very smoothly and produces high surface quality,' says Moosreiner. Further positive test results led to the decision to replace the previously used tool with the ISCAR innovation.
100 percent higher feed rates
MAN Energy Solutions has been working with the interchangeable head drilling system since 2022 and has achieved measurable success. 'The alignment has improved significantly. The holes now meet precisely,' reports Alexander Baier. Due to its good centering capability, MAN works with 100 percent higher feed rates compared to before. 'Our productivity has increased significantly,' summarizes Lukas Bachhuber. The tool is quickly ready for use on the high-performance machines.
'We save five euros per component. With 1,000 pieces per year, it pays off,' says Alexander Baier happily. MAN has increased the tool life by ten percent compared to the previous tool. In contrast, scrap costs have decreased. 'The holes are consistently within the specified tolerances,' says Lukas Bachhuber. The Augsburg team uses LOGIQ3Cham in diameters from 18 to 24 millimeters and drilling depths of 5xD and 8xD.
From the presentation to practical implementation, the cooperation with the ISCAR experts was exemplary. 'The contacts have existed for many years, and even in this project, we worked together openly, trustfully, and on an equal footing,' describes MAN expert Alexander Baier. LOGIQ3CHAM impressed MAN Energy Solutions all around. 'The precise and reliable machining with high feeds has led us to successfully use the tool on other components as well,' he summarizes.
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