Variety for all requirements
MAHLE supplies cast camshafts, forged steel or manufactured from a steel bar camshafts and composite camshafts for its worldwide customers. At the same time, both blanks and components ready for installation are produced in high volume unit numbers. The large product variety means that MAHLE is able to provide its customers with solutions optimally tailored to the specific application.
Chilled cast iron is primarily used for production. For higher loads in roller contact, cast camshafts with induction hardened cam lobes can be used. The shafts can be hollow cast cylindrically or profiled for weight reduction. The casting production is realized on state-of-the-art and fully automated production lines. A broad range of standard materials, but also special materials, is available for specific customer requirements. Modern machining centers and fully automatic CBN grinding machines guarantee a constant level of high quality.
Forged camshafts/steel camshafts manufactured from steel bar
Forged or manufactured from a steel bar camshafts are also used for certain high loaded diesel engines. These are produced on computer-controlled forging systems with integrated heat treatment or machined from steel bar.
As an essential contribution to optimizing the entire valve train, MAHLE has developed composite camshafts based on precision steel tubes with cam lobes made from steel and powder metal materials. Drive and drive gear elements are produced in line with the design using various production processes and materials. Composite camshafts from MAHLE are produced on state-of-the-art, fully automated production lines. The main features of these camshafts are:
- Precision steel tube with high torsional and bending stiffness
- Optional use of powder metal and steel cam lobes
- High angular accuracy during assembling
- High degree of design freedom in respect to the camshaft tube, camshaft bearing, add-on parts, materials, and integration in the engine lubrication
- High assembling precision without affecting the cam lobe profile
- Weight reduction of up to 45 percent in comparison to solid shaft camshafts
Precision powder metal cam lobes for roller actuation
The contact surface of the precision powder metal cam lobes does not require any grinding after the sintering. These cam lobes have been specially developed for the requirements of the roller contact. The use of precision powder metal cam lobes represents a cost-effective solution, especially in the combination of roller actuation with concave cam lobe profiles.
Steel cam lobes for roller and sliding actuation
Cam lobes made from steel are used for the highest loads. The materials used are distinguished by the highest rolling fatigue strength and good wear resistance.
Significant focus in the further development of composite camshafts are the development of materials and optimizing of the manufacturing process. Our goal is to considerably extend the application spectrum for the composite MAHLE camshafts.
Functional extensions for the composite camshafts, such as the actuation of fuel pumps or the integration of sensor components, are enjoying increasing use. The individual phasing of intake and exhaust cam lobes on a SOHC camshaft is obtained through MAHLE CamInCam®. In order to integrate further functions into the assembled camshaft, for example a swirl creator inside the camshaft may take over the function of oil separation from blow-by gas. The assembled camshaft can be equipped with roller bearings to reduce friction losses inside the engine.