The engine is responsible for generating the power necessary for the vehicle to move. Today, with the need to reduce emissions and improve power efficiency, engine development is becoming increasingly intensive.

New materials, regulations and other drivers bring significant investment in R&D. The main trend is the miniaturization of internal combustion engines in order to [sensitive word] minimize environmental impact. Another developing trend is the electrification of the powertrain.

Tessa Precision's solutions and tools for engine parts are backed by in-depth application expertise. With a professional engineering team that supports the automotive industry with multiple quality solutions, we have a strong presence in the international market as well. Here we share selected high-productivity solutions for some of the challenging characteristics of engine parts production.

cylinder block

The cylinder block serves as the primary structure of the engine, it is the housing for the many different moving parts that come together to produce the power needed to move the vehicle.

The cylinder block is the part that serves as the primary structure of the engine. It is the housing for the many different moving parts that come together to produce the power needed to move the vehicle.

For many years, engine cylinder blocks have been manufactured from cast iron alloys because of the material's strength, low cost, and wear resistance. However, as engines became more complex, new materials were used to reduce engine weight and improve strength and wear resistance. Today, the most commonly used material for passenger car engines is aluminum alloy, thanks to its lighter weight and excellent casting properties. Commercial vehicles will continue to use cast iron, but increasingly high-strength alloys.

The manufacturing process of the cylinder block involves a large number of machine tools in the production of automotive parts, as well as several complex processes and tight tolerances. The high quality requirements of the cylinder block are crucial to the performance of the vehicle. For these types of parts, economical manufacturing is very important.

cylinder head

The cylinder head delivers air and fuel to the combustion chamber and serves to cover the cylinder. It is also a housing for many different parts.

The cylinder head is used to deliver air and fuel to the combustion chamber, and since it is located on top of the cylinder block, it serves the purpose of covering the cylinder. It is also the housing for many different components such as valves, spark plugs, and fuel injectors.

In addition to the cylinder block, the manufacturing process of the cylinder head also involves a large number of machine tools in the production of automotive parts. In addition, several complex processes and tight tolerances are involved, especially when machining the valve seats and valve guides as well as the top surfaces. Since the cylinder head is an important part of the engine, its quality is critical to the vehicle's performance. Economical manufacturing is also very important for these types of parts.

crankshaft

This type of part is used to convert linear motion and power into rotational motion so that the shaft rotates and therefore the vehicle moves.

The asymmetrical and relatively slender crankshaft forms the heart of the internal combustion engine in all vehicles, from motorcycles to heavy-duty trucks. It is also one of the most challenging parts to machine. Considering the construction of the crankshaft, the high tolerance requirements and the challenging machinability of the material (forged steel or ductile iron), machining can only be successful with truly optimized tools and methods.

camshaft

The camshaft controls valve operation to synchronize the combustion cycle.

In internal combustion engines, the camshaft is used to control valve movement and synchronization. It consists of a shaft with multiple cam lobes, one for each valve. As the cam blades rotate, they exert pressure on the valve (or some intermediate mechanism) to force the valve open.

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Connecting rods are used to transmit linear motion from the pistons to rotate the crankshaft.

Connecting rods are used to transmit linear motion from the pistons to rotate the crankshaft. It is under enormous stresses from reciprocating loads, stretching and compressing with each rotation. Reciprocating load increases quadratically with engine speed. Unlike earlier methods of cutting off with milling cutters, big ends are now typically machined using cracking techniques. When cracking the big end, it may be necessary to pre-process a laser crack, which will place high demands on the subsequent boring process.

The connecting rod manufacturing process must be precise in critical tolerances and must be highly economical at the same time.