Turbocharger

Most of the compressors used in turbochargers today are radial compressors.

The air is suctioned axially by the rotation of the compressor wheel and accelerated in the wheel to high speeds. The accelerated air leaves the compressor wheel radially toward the diffusor.

In the diffusor, this kinetic energy is converted into pressure energy. In addition, the flow is delayed, pressure and temperature rise nearly without losses. This is achieved by the constant expansion of the flow cross-section within the spiral housing, in which the air is collected and the speed is reduced up to the compressor outlet. 

BAHMÜLLER offers various concepts and combination processing for the efficient complete machining of turbocharger rotors and shafts. What's more, there are various configuration options for conversion flexibility or single variant mass production.

 

 

Rotor / Turbo Wheel Contour

Specific components and process features:

  • wear-free through hydrostatics
  • highest quality through hydrostatic linear axes without reversal backlash
  • special "no burr" grinding process on wheel vanes
  • special tool loading + clamping technology for avoiding scratches / damage to bearing seat
  • CBN + conventional grinding wheels can be used
  • specifically configured dimensional check station integrated in processing machine
  • optimized cycle time through specific design measures (work piece loading)
  • simultaneous engineering through independent TEC center

This allows us to achieve:

  • course turbine wheel to shaft <8µm 
  • dimensional accuracy turbine wheel < 0.04
  • no downstream brushing of work pieces required

Shaft / Bearing Seats

Specific components and process features: 

  • wear-free through hydrostatics
  • highest quality through hydrostatic linear axes without reversal backlash
  • special work piece loading, clamping/carrier technology for driving work pieces between centers
  • without transverse force
  • in-process measurement technology
  • specifically configured dimensional check station integrated in processing machine
  • optimized cycle time through specially configured tools + processes
  • simultaneous engineering through independent TEC center

This allows us to achieve:

  • concentricity bearing seat < 5µm
  • surface Rz bearing seat < 1,7µm
  • surface Rk bearing seat < 0,6 
  • surface Rpk bearing seat < 0,18

Groove

Spezifische Komponenten und Prozessfeatures:

  • wear-free through hydrostatics
  • highest quality through hydrostatic linear axes without reversal backlash
  • special grinding process for dimensional + surface stability in groove processing
  • special tool loading + clamping technology for avoiding scratches / damage to bearing seat
  • CBN + conventional grinding wheels can be used
  • optimized cycle time through specific design measures (work piece loading)
  • simultaneous engineering through independent TEC center

This allows us to achieve:

  • axial run-out groove flank < 0.9 μm
  • right angularity groove flank < 0.35µm
  • max. diameter fluctuation < 0.004 mm
  • max. fluctuation of groove width < 0.003 mm

Processing can occur - as shown here - on individual machines.
However, we also have the option of representing the processing of all three on one machine (ULTRA FLOW).