Video on hot stamping to make parts

[Mike S]

Howdy...I found this very interesting video on how some parts are made. Around the 3:46 minute mark is how a crankshaft is formed followed by what looks like other automotive parts.
https://www.youtube.com/watch?v=hL6u5eWRBXM

Mike

[69Z28-RS]

Interesting...    (A forged crankshaft obviously)..  rather than cast...

[bcmiller]

Yes, forging. That's for a 5 cylinder engine.

Here is another more complete video on forging a crank.
https://m.youtube.com/watch?v=qGwA-nV82dY

Check this out, finishing after forging.
https://m.youtube.com/watch?v=dYy5lWj5LVk

[z28z11]

One crank at a time is a little slow. Current production rate per shift at GM Spring Hill and Nissan Decherd is hundreds per shift. Nissan forges their own, then finish machines, GM starts with an supplied forging and machines it. Machining cells are impressive to say the least, using turning, turn/milling and turn/broaching to rough and finish journals. Hyundai Montgomery does the same as GM.

I did get to see Mercedes V6 and V8 engine production in Stuttgart years ago; amid all the automation there was a guy by himself using crocus cloth/film tape to touch up journals by hand. Couldn't believe it when I saw it -

Regards,
Steve 

[BillOhio]

Very interesting thanks for the video Bryon

[bcmiller]

One crank at a time is a little slow. Current production rate per shift at GM Spring Hill and Nissan Decherd is hundreds per shift. Nissan forges their own, then finish machines, GM starts with an supplied forging and machines it. Machining cells are impressive to say the least, using turning, turn/milling and turn/broaching to rough and finish journals. Hyundai Montgomery does the same as GM.

I did get to see Mercedes V6 and V8 engine production in Stuttgart years ago; amid all the automation there was a guy by himself using crocus cloth/film tape to touch up journals by hand. Couldn't believe it when I saw it -

Regards,
Steve 

The point of the Lunati video is to show what is done. Yes, one at a time - because a decent amount of these are custom (stroke, rod journal size, counter weight details, etc). Not assembly line rate and made to tighter specs.

[z28z11]

One crank at a time is a little slow. Current production rate per shift at GM Spring Hill and Nissan Decherd is hundreds per shift. Nissan forges their own, then finish machines, GM starts with an supplied forging and machines it. Machining cells are impressive to say the least, using turning, turn/milling and turn/broaching to rough and finish journals. Hyundai Montgomery does the same as GM.

I did get to see Mercedes V6 and V8 engine production in Stuttgart years ago; amid all the automation there was a guy by himself using crocus cloth/film tape to touch up journals by hand. Couldn't believe it when I saw it -

Regards,
Steve 

The point of the Lunati video is to show what is done. Yes, one at a time - because a decent amount of these are custom (stroke, rod journal size, counter weight details, etc). Not assembly line rate and made to tighter specs.

I have no problem with any of that, with the exception of tighter specs. I'll take the millions of dollars in CNC state-of-the-art production and quality control equipment over a manual hand gage operation anytime. Tolerances are held to microns on machined surfaces on production cranks, liability is paramount.

[bcmiller]

Ok, well my thoughts did not get transferred into words very well.  And I rarely try to talk in absolutes.

I would venture to say that the tolerances at Lunati are tighter than what were in your First Gen Camaro originally, and are tighter than what you would get if done by most local machine shops.

Yes, tolerances at Tonawanda engine assembly are down much finer now (possibly as low as 8 microns) so I won't argue that. Sorry for any confusion I may have created.

The link was meant to be informative, not to start a debate.

[Z28Project]

Quite an operation!  Thanks.