MASCHINENFABRIK

ALFING KESSLER GMBH

AUTOMOTIVE CRANKSHAFTS
LARGE CRANKSHAFTS

ALFING Automotive Crankshafts

HARDENING EQUIPMENT

Crankshafts for series production,

sports and Formula 1

PASSION FOR PERFORMANCE

 Crankshafts: Thats our business!
With the ambitious aim ... of developing
and manufacturing more robust and wear
resistant crankshafts ..., Karl Kessler foun-
ded his own company in 1911.
This remains our ambition still today.
In the meantime the company is a leader in
technology and with over 1350 employees
one of the largest independent specialist
manufacturers of high-quality crankshafts
and induction hardening machines world-
wide.
But thats not all.
We are continuing to expand.
With crankshafts ranging from 300 to 8000
mm in length, ALFING covers a very wide
engine spectrum.
Karl Kessler on the 25th anniversary
of the company in 1936
As an engineer I travelled to different coun-
tries in Europe and North America and I be-
came aware that a high-quality product such
as an internal combustion engine crankshaft
would be a suitable product for manufacture
in my German homeland. With this in mind I
returned from North America.
Crankshafts for more power
In the beginning, large crankshafts were
ALFINGs main focus:
For example the aircraft engines in the Zep-
pelin airships made ALFINGs name known
all over the world.
As early as 1932 ALFING became closely in-
volved in car racing:
6 cylinders, 300 HP and more than 235 km/h.
> Mercedes-Benz SSKL
> Auto-Union
... and others were soon to follow.
And in their engines:
The worlds first racing crankshafts ...
... from ALFING.
Ever since, one can hardly think of car engi-
nes without thinking of ALFING crankshafts.
We are experts in the manufacture and harde-
ning of crankshafts for automotive, racing and
large engines for almost every conceivable
application and major engine manufacturer
worldwide.
ALFING is the partner for its customers
crankshafts over the entire life of the engine:
From planning, optimisation, project manage-
ment, process development, logistics, quality
assurance, material procurement, forging,
heat treatment, mechanical machining,
surface treatment, assembly, testing through
to after-sales service and support.
This is how we have become global market
leader in high-performance crankshafts and
hardening equipment.
Karl Kessler Auguste Kessler
 At home in engines
MASCHINENFABRIK
ALFING KESSLER GMBH

worldwide
AUTOMOTIVE CRANKSHAFTS
LARGE CRANKSHAFTS
HARDENING EQUIPMENT

History of the
Maschinenfabrik ALFING Kessler

1911 Founding of the Maschinenfabrik ALFING Kessler GmbH by Karl Kessler (1880-1946)
1913 Delivery of the first case-hardened crankshafts
1932 Focus on the production of crankshafts for aircraft engines for airships
and transport planes
1935 Establishment of the special-purpose forge for crankshaft forgings
1946 Death of company founder Karl Kessler
1947 Auguste Kessler takes charge of the company
1951 Manufacture of the one millionth crankshaft
1952 First induction hardening machine for crankshafts
1960 Death of Auguste Kessler
1970 New production shops for large crankshafts
1990 Expansion of the production facilities for automotive crankshafts
1995 Establishment of a separate production department for motor sports and
prototype crankshafts
2003 Reorganisation and targeted market segmentation of the company
2004 Expansion of automotive crankshaft production
2005 Expansion of large crankshaft production
2006 Manufacture of the seven millionth crankshaft
2007 ALFING again invests in further expansion of crankshaft manufacture

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 Whatever the make of the engine ...
ALFING is usually inside
Energy and mobility are fundamental cor-
nerstones of business and the economy.
Worldwide.
This calls for high-performance engines on
land, on sea and in the air.
And high-performance crankshafts ...
... thats our job.
4
The continuously increasing demand for
greater engine performance and efficiency
calls for higher performance components
starting with the crankshaft.
That is why ALFING has become a specialist
in the surface treatment of crankshafts to
increase performance.
Whether powerful diesels for Sports Utility
Vehicles (SUV), high-speed engines for
Formula 1, stationary engines for power
generation or ship diesels:
Optimal continuous power is what our
customers demand from their crankshafts.
To achieve this we offer:
> development support
> process reliability
> high-quality manufacturing
> fatigue strength
> low wear
> performance enhancement ...
... because thats what our customers
expect.
 MASCHINENFABRIK
ALFING KESSLER GMBH

ALFING: AUTOMOTIVE CRANKSHAFTS

LARGE CRANKSHAFTS

Partner ...
HARDENING EQUIPMENT

for perfect
mobility

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 Crankshafts: Thats what we know about
Almost from the beginning of motoring,
Karl Kessler was involved in the manufac-
ture of crankshafts.
This is what ALFINGs almost one hundred
years of experience is based on.
And from where all our fields of activity and
divisions have developed.
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LARGE CRANKSHAFTS
DIVISION
Manufacture of large crankshafts ready for
assembly.
Lengths up to approx. 8000 mm
Swing diameter up to approx. 900 mm
Performance up to approx. 12 000 kW
Speeds up to approx. 3000 rpm
Our core competences:
Technological development, project and
quality management and logistics.
One-off and series production.
Forging and heat treatment of crankshafts.
Rough machining, surface treatment, finish
machining, manufacture of accessories and
crankshaft assembly.
From project planning
to crankshafts ready to install.
HARDENING
DIVISION
Development and production of
induction hardening equipment.
Lengths
up to approx. 1500 mm
Cylinders up to 24
Engine types In-line engines
V-engines (with or
without split-pins)
boxer engines
Our core competences:
Individual and modular machine concepts.
Design and integration of hardening equip-
ment in the customers production line.
Consequent application of ALFINGs harde-
ning experience gained in our own crank-
shaft production to customers productions.
Fastest hardening process technology in
the world.
Hardening machines based on
modular machine components
 ALFING
AUTOMOTIVE
Competence MASCHINENFABRIK
ALFING KESSLER GMBH

AUTOMOTIVE CRANKSHAFTS
CRANKSHAFTS LARGE CRANKSHAFTS
DIVISION HARDENING EQUIPMENT

Manufacture of crankshafts ready to install

in automotive and industrial engines.
Lengths up to approx. 1000 mm
Performance up to approx. 850 kW
Speeds up to approx. 20 000 rpm

Our core competences:

Technological development,
project and quality manage-
ment and logistics.
All the necessary
manufacturing processes,
perfect surface treatment
and mounting of auxiliary components ready
for installation of the crankshaft.

From prototype to series manufacture ...

... all on one site.

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 Overall competence is our strength

OVERALL COMPETENCE is written large at

ALFING and means:
One partner ... from the customer require-
ment, to process development, to delivery Component testing:
of the crankshafts ready to be installed. Prototype fatigue strength,
manufacture torsion, bending
Material testing
&optimisation
OVERALL COMPETENCE is also synonymous
Process development
with: highly skilled personnel.
for increased
productivity

CAD-FEM-
simulation
SIMULTANEOUS ENGINEERING
This is why ALFING places great emphasis
on having well trained personnel through Customer drawing
its own apprentice training workshops and Specification,
systematic personnel development. Functional
requirements
Logistics
Was
Just-in-time delivery
Residual d

ALFING COMPETENCE: More than just crankshafts

Within the scope of Simultaneous Engi- Needless to say we are experts in the Rough machining, surface treatment/
neering together we can help optimise whole logistics chain, process develop- hardening, finish machining and as-
your crankshafts from the point of view of ment, tool and jig design and of course sembly ... ALFING offers you the whole
performance, cost and design. the machining processes too: value-added chain at a single site.

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 All ... MASCHINENFABRIK

... under one roof

ALFING KESSLER GMBH

AUTOMOTIVE CRANKSHAFTS

www.alfing.de

Preparation of drawings,
optimisation, design
CAD/CAM

MANUFACTURING PROCESS Materials

testing

Rough machining

Surface treatment
& hardening

Finish machining
shing Assembly
dirt analysis QM/QS

Crankshaft production at ALFING 9

using our own induction hardening machines
 Automotive Crankshafts
The pillars of the division
From prototype development via
pre-series production to series production,
we are your confidential, reliable and
competent partner.
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Whether cast or forged crankshafts, one-
off or large batch production, crankshafts
for combustion engines or pumps and
compressors, for single cylinder or 16-cylinder
engines:
ALFING supports its customers with
comprehensive expertise during the whole
development of a new engine.
We provide optimal manufacturing facilities for
almost any batch sizes.
We offer our customers a dependable
crankshaft manufacturing process, assuring
highly precise geometry and excellent surface
finishes.
One of our outstanding qualities is ALFINGs
versatility and know-how concerning surface
treatment.
Here ALFING is able to offer all the well known
surface treatment processes in-house.
PROTOTYPES
Thanks to our flexible manufacturing facili-
ties, we are able to produce crankshafts in
the smallest batch series even one-offs
for almost any kind of engine.
Such requirements often concern the la-
test engine developments with correspon-
dingly new demands on the crankshaft.
The overall crankshaft development pro-
cess at ALFING is routinely carried out un-
der the utmost secrecy in isolated, access-
controlled departments.
Even top racing leagues such as
Formula 1, NASCAR and the DTM are
pleased to take advantage of our exper-
tise and our discretion.
We would be pleased to tell you more
in person naturally in confidence.
AUTOMOTIVE CRANKSHAFTS: Comprehensiv
 From prototypes
to series production
MASCHINENFABRIK
ALFING KESSLER GMBH

AUTOMOTIVE CRANKSHAFTS

SERIES AND www.alfing.de

FLEXIBLE
MANUFACTURING

ALFING has various highly automated

production lines for different series requi-
rements.
On these we produce crankshafts ...
completely finished, ready for installation
and with all the accessories.
We also have production lines designed
for quantities exceeding 100 000 cranks-
hafts of one type per year.
Of course in consistent quality. This is
maintained by our universal quality assu-
rance process.
Series and flexible manufacture at
ALFING ... based on:
> State-of-the-art manufacturing
technology,
> State-of-the-art measurement
technology,
> State-of-the-art measuring machines,
> State-of-the-art testing laboratories.

ve range

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 ALFING Automotive Crankshafts:
Prototypes
Both in motor sports and in prototype
development, the demands as to flexibility
and quality are on the increase.
At the development stage of a new
crankshaft, being able to draw on ALFINGs
overall experience gives you a decisive
competitive advantage.
Every customer requirement can be taken
into account here.
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> CAD data transfer between all
customer systems
> CAD & FEM simulation
> CAD balancing analysis, e.g. concer-
ning lightening holes and web shapes
ENGINEERING
LOGISTICS
AUTOMOTIVE crankshafts: PROTOTYPE manufacture - the ultimate level in ALFING flexibility
Even where the customer has not yet got
a forging, ALFING can still deliver the
finished crankshaft.
In this case we can make the blank from
solid material a so-called free-form shaft.
> Development of new processes to
improve crankshaft performance
> Material testing & analysis, e.g. to
investigate the effect of the different
surface treatment processes
PRE- & INTERME-
DIATE MACHINING
Also for the required manufacturing
processes, ALFING is able to test and
optimise tools, cutters, etc. in cooperation
with the customers.
> highly confidential
> Test benches for fatigue strength,
torsion and bending
> Advice on materials & alternative
materials.
> Advice on design, e.g. fillet radii of
main & pin bearing, web shapes
SURFACE
TREATMENT
ALFINGs support of its customers with
crankshafts over the whole development
process of the new engine is
> highly competent
> very flexible
> and very fast
 Want to build MASCHINENFABRIK
ALFING KESSLER GMBH

a new engine? AUTOMOTIVE CRANKSHAFTS

www.alfing.de

The results of customers engine trials

usually need to be quickly implemented
in modified crankshafts. This not only calls
for great flexibility but also tight project
management with integrated logistics.

FINISH ASSEMBLY
MACHINING

As soon as the customer has perfected
and tested his engine, we also support
him flexibly with the series production.
Should the customer wish to produce the
crankshafts on his own production lines
... ALFING will provide the crankshafts
required for start-up: appropriately
machined for every stage in the process
and for every station.
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 ALFING Automotive Crankshafts:
Series and flexible production

ENGINEERING PRE- & INTERME- SURFACE

LOGISTICS
LOGISTIK DIATE MACHINING TREATMENT

Our customers are manufacturers of
series and premium vehicles:
High-quality series vehicles with high-
performance engines.
High-performance engines with high-
performance crankshafts.
> Materials advice
> CAD alternatives
> FEM simulation
> Preparation and testing of
possible variants
The ability to produce batch sizes from
> Manufacturing and cost
approx. 100 parts to over 100 000
optimised design
crankshafts of each type per year ...
> Balancing analysis on a CAD model
... those are our batch sizes. > Development of procedures to
increase performance
> Validation of the results through
On our production lines we produce fatigue testing
crankshafts for all types of engine:
from one to 16 cylinders ...
... and in a highly flexible way.
The cutting processes are carried
out on our interlinked high-
performance CNC machines:
> Turn-milling
> Turn-broaching
> Drilling
> Deep-hole drilling
> Internal/external
deburring
> Gear tooth forming
using the latest tool and cutting
means technology.
> Gas nitriding
> Gas nitro-carburising
> Radius rolling
> Induction hardening and
annealing
These are the surface treatment
processes most commonly
requested by our customers.
For these processes, ALFING has
its own patented procedures.
Especially in the case of induction
hardening and annealing, ALFING
can offer its customers practical
experience gained over 50 years
from its own hardening machine
and inductor manufacture.

To do this we need very efficient logistics: No wish regarding increased

from electronic requests via the whole performance and wear reduction
development and production process is left open.
chain to just-in-time delivery.

Even customers who have not yet used

our expertise for the development of
their prototype crankshaft are pleased to
take advantage of our optimisation and
manufacturing know-how for their series
production. AUTOMOTIVE Crankshafts: The complete infrastructure ... you can depend on.

14

FINISH
MACHINING
> Corundum grinding
> CBN grinding
> Super-finishing
> Dynamic balancing
> Automatic washing machines
> Residual dirt analysis
ALFING finish machining is highly
automated, e.g. through the
use of robots and synchronised
conveyor systems.
Passion for MASCHINENFABRIK
ALFING KESSLER GMBH
ASSEMBLY
Performance AUTOMOTIVE CRANKSHAFTS
www.alfing.de
> Mounting of accessories
> Final inspection
> Classification according to
measuring results
> Laser engraving
> Preservation and packing
ALFING assembly is the final
step in the production process
from forging blank to the finish
assembled crankshaft ready for
installation.
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 No compromises ...
the basis of our success

Compliance with the standards
ISO/TS 16949:2002 and
DIN EN ISO 14001:2004
has for many years assured that ALFING
satisfies the highest quality and environ- > Constant self-testing by the operator
mental demands.
Furthermore our in-house testing and
laboratory technology satisfy the most > Final inspection of each individual
stringent customer requirements.
All necessary information can be engra-
ved on the crankshaft at the customers
request, e.g. in dot-matrix code.
Totale Totale
Our multi-layer quality system has proved its
value in practice: Kurbelwellen-
Total Ku
crankshaft competence
kompetenz rbelwellenkompetenz
> Quality planning
The world renowned ALFING
> First part acceptance after each operation competence is continually being
further expanded through our
Basic Development.
> Quality assurance based on the inspection
plan For this ALFING developers have
an extensive array of state-of-the-
art laboratory, measuring and test
crankshaft equipment at their disposal, lea-
ding to patents which protect our
know-how worldwide:
> CAD-FEM simulation of So that you, too, can benefit
crankshaft from these developments, we
offer you our Competence
> Development of processes to
as a service for crankshaft opti-
increase crankshaft performance
misation.
within the given available space
Where necessary we can even
> Material testing
develop special-purpose machi-
> Trials for component strength nes to implement the newly de-
and component optimisation veloped process in practice.
> Balancing analyses on the CAD
model
> etc.

ALFINGs environmental policy commits the Environmental protection at ALFING is an

company to compliance with all environ- integral part of management and is lived
mental laws and regulations. out in practice. We demand environmental
awareness and commitment from all of our
By proactively taking into account the ef-
employees.
fects on the environment, ALFING aims to
To assure optimal environmental protection,
avoid emissions and make economical use
our procedures are certified at regular inter-
of energy resources.
vals by internal and external audits.
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Technology assures MASCHINENFABRIK
ALFING KESSLER GMBH

our quality AUTOMOTIVE CRANKSHAFTS

www.alfing.de

17
 Whats in it for you?
Maximum performance, quality and
added value.
The high demands of our customers
keep us on our toes.
This is where our leadership in innovati-
on and quality results from.
That is how it should be ...
... because it is to your advantage.
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We incorporate the solutions to these
challenges in the form of research,
development, education & training,
technology and productivity ...
... into our daily work.
This is what ALFING offers you
Solid tradition, modern management, decades of experience
+ Know-how about crankshaft technology
+ Understanding of how engines are designed and work
+ Competence in crankshaft manufacture
+ Modern manufacturing technology
+ Perfect quality management
+ Comprehensive project planning
+ Know-how in materials technology
+ Increased engine performance through surface treatment
+ Complete testing, measurement and laboratory technology
+ Reliable processes, precise logistics
+ Know-how about induction and hardening technology
+ Modular components for hardening machines
+ Services, hotline & support around the clock
+ On-going investment in production facilities
+ Continuous further education and training
______________________________________________
= Leading the field
Competence, technology, quality
Win-Win ...
with crankshafts
MASCHINENFABRIK
ALFING KESSLER GMBH

AUTOMOTIVE CRANKSHAFTS

from ALFING www.alfing.de

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Maschinenfabrik
ALFING KESSLER GmbH
Automotive Crankshafts Division
Auguste-Kessler-Strasse 20
73433 Aalen / Germany
Tel. +49 (0)7361 - 501-4411
Fax +49 (0)7361 - 501-4408
automotive@mafa.alfing.de
www.alfing.de