A set of samples of crankcase oil pans for testing of the latest R6 engine was made at the Press and Stamping Plant of KAMAZ (part of Rostec State Corporation).
Unique die tooling was designed and manufactured very fast, though constructors and technologists hadn't developed tools for the manufactrure of such a detail before. "Our main challenge was the 334 mm depth of the case," Dmitry Postnikov, Deputy Chief Technologist for Preproduction, noted. "For example, KAMAZ's case is simpler and shorter by 100 millimeters. But, nevertheless, we did it."
Five dies have been made for four months. Each of them is 2.6 m long and 1.7 m wide weighing 15-19 tonnes and consisting of neatly mounted and processed alloy castings. One such die costs several million roubles. According to Larisa Chistyakova, Chief of Bureau of Material Processing Methods, the analysis of the numerical scheme of the crankcase oil pan showed that in the first place it is necessary to find equipment for its manufacturing. "Our Aida press which stamps KAMAZ's series pans doesn't suit both in detail parameters and in force. We had to take a risk and develop a technology for a more powerful line consisting of separate presses," she told. "After all disputes we decided to act step-by-step and gradually press the necessary depth using three presses one by one. The fourth die was needed for calibration, the fifth one was for cutting."
It should be noted that all participants of the project worked quickly and efficiently, a great contribution was also made by IT experts who prepared a software for CNC machines.