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Manufacturing Systems for Precision Metal Components

High productivity with a minimum fl oor space requirement – that is what you get with the vertical, fully automated VL 2 turning machine from EMAG.This is where it all comes together – this CNC turning machine requires very little fl oor space, is easy to operate and self loads by means of an integrated automation system. The machine can be set up in a single step – without the need for additional robots or gantry loaders. Above all, high quality machine components together with EMAG classical vertical machining ensure high quality machining.

Conclusion: an extremely productive turning machine with high quality components which is highly fl exible to use.

+ 15 %+ 30 %

020 %40 %60 %80 %

100 %120 %140 %

Manually loading a horizontal turning machine

Automated horizontal turning machine

EMAG VL 2 EMAG VL 2 P

Vertical machining: increases productivity considerably

Turning Down the CostsVL 2 PICK-UP TURNING MACHINE

EMAG VL 2 P: the Idle Time Killer Short idle times: the VL 2 P needs just 1.5 seconds for workpiece changeover. Two main spindles are used for this purpose. While the fi rst spindle is busy machining a workpiece, the second spindle loads itself automatically using the pick-up technique.

The machine scores particularly well when it comes to workpieces requiring short machining times. The main criterion for assessing the economy of a machining process is the ratio between machining time and idle time.

Maximum workpiece sizes

VL 2 VL 3 VL 5 VL 7 X- / Y- / Z-axis travel 650 / 100 / 400 mm 400 / 50 / 200 mm 660 / - / 300 mm 850 / - / 315 mmMain drive unit 19.5 kW / 75 Nm 24 kW / 158 Nm 28 kW / 300 Nm 45 kW / 775 NmMax. number of revolutions 6,000 min-1 7,500 min-1 4,500 min-1 3,400 min-1

Overview of the VL series

100 130 250 340

150

145 17

5

160

m2 5AUTOMATION

USING MINIMUM FLOOR SPACE

2

THE BENEFITS OF THE EMAG VL 2

VERTICAL MACHINING: SAFE AND EFFICIENT

5

RAPID PERFORMANCEShort distances for machining and loading ensure very short cycle times.

1

MINIMUM FLOOR SPACE REQUIREMENTThe VL 2 takes up only fi ve square meters.

2

FULL AUTOMATIONThe workpieces are changed by the automation system – with more than 40 workpieces on the storage conveyor. The simple automation concept ensures high availability.

3

STURDY CONSTRUCTIONThe machine body made of MINERALIT® polymer concrete ensures high rigidity and excellent vibration damping. This directly benefi ts the machining quality.

4

SIMPLE HANDLINGAll the service units are freely accessible, therefore, easy to reach. Changing tools is also very simple – just 270 mm distance to the tool turret.

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EMAG NEWS 21

Manufacturing Systems for Precision Metal Components

VLC 100 G: Cause and eff ect

Compact design » Low space requirement

Internal and external grinding spindles can be used» Fast production process

Integrated automation system with short travel distances » Short chip-to-chip times

Vertical machining with free fl ow of chips » Very high process reliability

Optimum accessibility » Short tooling and retooling times

Probe (optional) » High process reliability

A lot of small chucked parts are required in very large quantities. The VLC 100 G grinder is the effi cient pro-duction solution.Gears, planetary gears, chain wheels and fl ange parts are required in millions of units in the automotive sector. The VLC 100 G grinding machine is a leap forward in performance while requiring a minimum of fl oor space (just 5.7 square meters). This is made possible by the typical EMAG integrated automation. The machine loads itself with a pick-up spindle from the integrated conveyor belt. The conveyor belt is loaded and unloaded by the operator or a suitable handling system. The chip-to-chip time is minimal.

Conclusion: the extremely compact grinding machine with automation system speeds up production processes substantially.

Large Quantities, short Cycle Time

VLC 100 G GRINDER

VLC 100 GChuck diameter max.: 160 mmMachining diameter max.: 100 mmGrinding length max.: 150 mmX-axis travel: 650 mmZ-axis travel: 400 mm

5.7 FOOTPRINT

JUST

m2

UP TO TWOGRINDING WHEELS IN A SINGLE MACHINING AREA

4

CYCLE TIMES OF ONLY SECONDS – FOUR TYPICAL SUCCESS STORIES

VG 110: Non-circular grindingNon-circular operations such as profi le grinding of pump rings

Chuck diameter: 100 – 190 mmSwing diameter: 125 mmMachining diameter max.: 60 mmWorkpiece diameter (nominal): 100 mmX-axis travel: 460 mmZ-axis travel: 225 mm

VLC 250 DS: Multi-technologyTurning, hard turning, internal and external grinding all on a single machine

Chuck diameter: 250 / 315 mmSwing diameter: 350 mmWorkpiece diameter (nominal): 250 mmX-axis travel: 1,400 / 1,600 mmY-axis travel: ± 100 mmZ-axis travel: 300 mm

GEAR WHEELMachine: VLC 100 GTechnology: internal circular grindingMaterial: 20MnCr5Cycle time: 22 SeC.

CYLINDER SLEEVEMachine: VLC 100 GTechnology: internal circular grindingMaterial: 27SiMnCycle time: 20 SeC.

PUMP RINGMachine: VG 110Technology: non-circular grinding of internal contourMaterial: 100Cr6Cycle time: 30 SeC.

GEAR WHEEL WITH INTERNAL POLYGONMachine: VLC 250 DSTechnology: turning, drilling, thread tapping and non-circular grinding of the internal polygonMaterial: 16MnCr5Cycle time: 55 SeC.

22 SeC.

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EMAG NEWS 21

Manufacturing Systems for Precision Metal Components

Large Parts – Massive Effi ciencyVLC 500 MT MULTI-TECHNOLOGY CENTERS

MAIN SPINDLE CAPACITY FOR FAST

PROCESSES

110 kW

6

Large Parts – Massive Effi ciencyTHE VLC 500 MT

MULTI-FUNCTIONAL: Turning, drilling, milling and grinding in a single system

COMPLETE:Machining in a single clamping operation

STURDY:Vibration dampening and thermal stability thanks to machine base and compound slide made of MINERALIT®

polymer concrete

SAFE:Thanks to integrated measuring system

FLEXIBLE:Standardized automation modules ensure high fl exibility

INTELLIGENT:Vertical design ‒ideal downward chip fl ow conditions

SIMPLE:Easier operation thanks to user comfort and very good accessibility

COMPACT:Small footprint due to compact design

Automated complete machining of large workpieces

IMPORTANT KEYWORDS

FOR EXAMPLE WIND POWER: SIX AT ONCEOne manufacturer uses the VLC 500 MT from EMAG for manufacturing six diff erent components required for driving the gondola on a wind turbine. Up to twelve tools are used for this purpose.

Technologies: turning, milling and drillingClamping device: EMAG special purpose clamping chuck for all workpiece variantsMaterials: cast iron, steelWorkpiece variations: six pieces

TURNING, DRILLING, MILLING, GRINDING AND

MORE IN A SINGLE SYSTEM

96 TOOLS

Do you want to perfect the machining of drive housings, planetary carriers, hollow wheels and other large com-ponents? The VLC 500 MT provides maximum productivity.Whether in wind turbine construction, commercial vehicle production or train engineering the challenges are massive with large, heavy components that have to be machined safely and with the highest precision. The multi-functional VLC production centers from EMAG are based on a vertical complete machining process with a single clamping operation. The large compo-nent is collected by the pick-up spindle and machined on all sides. Up to 96 tools are available for turning, drilling, milling, grinding and more.

Conclusion: the VLC 500 MT ensures fl awless, high speed machining of large components. The component quality benefi ts, the process sequence is highly effi cient.

Chuck diameter: 500 / 800 mmSwing diameter: 820 mmPower rating of main drive unit: 74 / 110 kWMax. torque: 1,300/ 4,400 NmRapid-traverse rate X / Z: 45 / 30 m/minMilling spindle: 40 kW / 320 NmTool carrier: 1 x tool turret with up to 12 driven tools, 1 x milling spindle with tool changer for max. 96 tools with HSK 100 tool socket

MACHINE DATA

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EMAG NEWS 21

Manufacturing Systems for Precision Metal Components

MAXIMUM: 4-AXIS TURNING WITH 2 X 11 TOOLS ENSURES MAXIMUM PRODUCTIVITY

Setting the Pace for Shaft Production

VERTICAL TURNING MACHINE VT 2-4

COMPLEX GEOMETRY – LARGE QUANTITIES: Shaft machining is a challenge for production planners.

The workpiece changeover time on the VT 2-4 is just six seconds. When large quantities are machined, this small number means a massive benefi t in terms of costs.Mass and class – this 4-axis vertical turning machine scores points in every respect for machining large quantities of shafts up to 400 millimeters in length. The secret is integrated automation and short axis movements: while one workpiece gripper loads a new part into the machine, the other one unloads a fi nished part. With spindle speeds up to 6,000 r/min the turning process is completed very quickly. The shaft is machined very precisely in a vertical orientation from two sides.

Conclusion: automation, 4-axis machining and a powerful main spindle guarantee highly effi cient shaft production. This results in a massive reduction in costs per part.

8

Z1W

X1

A1C

A2

Y1

Z2

X2

Y2

Setting the Pace for Shaft Production

COMPLEX GEOMETRY – LARGE QUANTITIES: Shaft machining is a challenge for production planners.

Productivity comes standard:» including raw and fi nished parts storage units – no additional procurement costs for automation and peripherals» small footprint due to compact, vertical design» can be used as a stand-alone machine or as part of a manufacturing system» free fl ow of chips prevents chip clusters» less manual intervention required (headstock and steady rests can be moved under CNC control, the operator has direct access to the tool turrets)

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SHORT MACHINING TIMES » thanks to effi cient 4-axis machining

2

SHORT IDLE TIMES» due to simultaneous loading and unloading

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SHORT TOOLING AND RETOOLING TIMES » thanks to excellent accessibility and ease of operation

The complete VTC series

Maximum workpiece sizes

VTC 100-2 VTC 100-4 / VT 2-4

VTC 250 / VTC 250 DUO

VTC 315 / VTC 315 DUO

X- / Z-axis travel 340 / 625 mm 340 / 625 mm 300 / 740 mm 390 / 950 mmMain drive unit 19.5 kW / 75 Nm 34 kW / 144 Nm 38 kW / 250 Nm 38 kW / 650 NmMax. number of revolutions 6,000 min-1 6,000 min-1 5,000 min-1 4,000 min-1

6 IDLE TIMES

REDUCED TO A MINIMUM

SEC.

63 63 140 250

400

400

7001,

000

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EMAG NEWS 21

Manufacturing Systems for Precision Metal Components

More productiveThe high drive rating (15 kW) at the grinding wheels ensures short machining times. In addition, all cylindrical grinding operations can be completed in a single clamping operation if two or three grinding wheels are used.

SaferThe initial balancing process is carried out with gap and crash detection. In addition, process control benefi ts from in-process measurements (external diameter and longitudinal positioning) on the component shoulders.

More preciseAbsolute measuring system (glass scales) ensures maxi-mum machining accuracy. This is supplemented by high precision, rigid linear roller guide ways in all axes.

HIGH PRECISION: DIFFERENT SHAFTS CAN BE MACHINED ON THE HG 2

Perfect cylindrical grinding is a matter of a few microns. The high precision process must run 100 % capable and effi ciently even in mass production. The HG 2 cylindrical grinder is designed to ensure this aspect. It has a high drive rating at the grinding wheel to ensure extremely short grinding times. In addition, the high precision axis roller guide ways and the thoroughly rigid construction ensure particularly high machining quality. And of course the entire process is monitored perfectly.

Conclusion: grinding quality comes standard, the HG 2 with its wide range of high tech components is a giant leap forward in terms of performance.

Nowhere is quality, precision and process reliability more important than in cylindrical grinding. The HG 2 stands out in this respect.

Maximum Quality comes Standard

The HG 2 at a glance:» Short machining times due to high grinding wheel drive rating » Balancing operation with gap and crash detection to monitor the process» In-process measurement of external diameter and longitudinal position on the shoulders» High precision, rigid linear roller guide ways in all axes» Absolute measuring system (glass scales) in all axes ensures maximum

machining accuracy» NC tailstock with large stroke for easy retooling» High productivity due to short idle times» User-friendly workpiece correction system» Very simple handling with control and setup masks» Large doors and low distance to workpiece

Workpiece diameter max.: 200 mmWorkpiece length max.: 400 mmX-axis travel: 360 mmZ-axis travel: 1,000 mm

COMBINED GRINDING COMPETENCEWhether for small crankshafts or a six meter crankshaft for shipbuilding, EMAG develops customized machining solutions.HG 2 HORIZONTAL CYLINDRICAL GRINDER

The HG 2 at a glance:

Balancing operation with gap and crash detection to monitor the processIn-process measurement of external diameter and longitudinal position

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THE LATEST CBN TECHNOLOGY IS THE KEYEven complex shafts can be ground with high precision (photo, center). CBN grinding wheels are used for cam profi le grinding of camshafts for motorcycles, cars and trucks (photo, right).

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EMAG NEWS 21

Manufacturing Systems for Precision Metal Components

Many users know the challenge: pinions and wheels, worm gears and screws are required in greater numbers of versions. However, quantities are reducing and companies must be able to react very quickly to new customer requirements.In light of this, EMAG KOEPFER has used the very latest technology in the K 200 gear hobbing machine: at least eight activated CNC axes and a fully automatic loading system make for an extremely fl exible system which is tailored precisely to suit the specifi c needs of the customer. Another benefi t is that the components can undergo initial soft milling and hard fi nal machining with guaranteed high quality.

Conclusion: The K 200 gear hobbing machine provides maximum fl exibility and effi cient processes.

K 200 GEAR HOBBING MACHINE

Requirements for gear hobbing are rising with a wide range of components that have to be machined fl exibly and quickly on a single machine. The K 200 gear hobbing machine provides a universal answer to this.

Universal Solution for the Production of Gears

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Gear hobbing machineModule max. Workpiece diameter mmCutting distance mmWorkpiece length mmCutting width mmShift distance mmMain spindle speed rpmCutter speed rpm

FIVE KEYWORDS

1 COMPLETE Soft milling (axial, radial or tangential milling) and hard machining on a single machine

2 PRECISE Gear hobbing up to quality 6 to DIN with excellent vibration dampening thanks to the MINERALIT® polymer concrete body

3 FLEXIBLEAutomation solution for a wide range of raw parts (manual loading also possible)

4 UNIVERSALSuitable for every hobbing profi le geometry

5 CUSTOMIZEDMany special applications and machine options available

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PRECISION GEAR HOBBING

TO HIGH QUALITY

TO DIN

KOEPFER GANTRY LOADING PORTAL The KOEPFER gantry loader with V gripper provides the basis for intelligent, variable automation.The raw and fi nished part magazines are available for a range of parts (in this case a “sloping level” with belt storage unit). Long term magazines for wheels and shafts mean that machines can operate for several hours at a time.

K 200 3 120 / 180 200 300 130 / 100 100 / 70 450 / 1,000 2,400 / 3,000 / 5,000

K 160 2,5 90 / 140 200 / 480 300 / 1,000 250 160 4,000 5,000

K 300 4 140 / 195 300 300 / 800 200 160 800 2,500 / 4,000

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EMAG NEWS 21

Laser welding is essential for the production of many automotive components. EMAG systems provide an extraordinarily effi cient process, including lower energy consumption.

Laser welding is often synonymous with effi cient lightweight construction methods, the weld replaces (heavy) bolt connections and the components are therefore lighter. To ensure an effi cient production process, EMAG develops customized solutions for every application on the basis of its ELC series. The machines load themselves with a pick-up spindle and the stationary laser optics then ensure high precision welding results. One other benefi t: the specialists can develop the complete process chain for a component from the initial turning to inspection processes.

Conclusion: ELC systems ensure a high precision, high speed and energy-effi cient welding process.

Perfecting the Laser Welding Process

ELC SERIES

ELC 200 H: Designed for shafts

» For drive shafts, propeller shafts, steering shafts and similar workpieces

» Horizontal spindle and NC tailstock designed for parts of diff erent sizes» Can be fi tted with all laser technologies

ELC 160: Maximum fl exibility

» Modular system concept for the production of medium to large quantities» Triple-axis NC machining with stationary pro-

cess modules (including optics)» Can be fi tted with all laser technologies

ELC 250 DUO: Multi-functional

» Pick-up spindle» Lower idle times: two machining stations

“share” the laser source (loading and unloading during the machining time)

» Complex follow-up machining included (for example brushing and inspecting)

» Can be fi tted with all laser technologies

50 % LESS ENERGY

CONSUMPTION

SOLID-STATE LASERSEMAG is the technology leader in the use of solid-state lasers for transmission components. The effi ciency of the solid-state laser is much higher than of a classic carbon dioxide laser. This means that energy consumption for the production can be reduced by up to 50 %.

– 50%

CO2 laser Solid-state laser

Ener

gy s

avin

gs

0

20

40

60

80

KW

10090

70

50

30

10

Output Cooling capacityWaste heat

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HIGH SPEED PROCESSES – FOUR APPLICATION EXAMPLES

MINIMUM DISTORTION DESPITE HIGH WELDING SPEED

GEARSLaser welding a synchronizerring to the gear.Welding / Jointing process time: i2 Sec.

DIFFERENTIAL HOUSINGLaser welding a ring gear to the diff erential housing. Welding / Jointing process time: 35 Sec.

GEAR SHAFTLaser welding the synchronizer wheel to the gear shaft. Welding / Jointing process time: I6 Sec.

PROPELLER SHAFTAssembling the propeller shaft from three single components.Welding / Jointing process time:

I4 Sec.

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EMAG NEWS 21

Manufacturing Systems for Precision Metal Components

FUEL INJECTORS: High Requirements A great deal depends on the high precision machining of the fuel injectors in modern automotive engineering. Despite the fact that the cubic capacity continues to fall, engines develop more and more power while at the same time their fuel consumption is sinking. One of the factors that makes all this possible is the extremely precise supply of highly pressurized fuel. This also places high precision requirements on the fuel injector. Ultimately, a few thousandths of a millimeter determi-ne the effi ciency of the component.

MAXIMUM PRODUCTIVITY: THE PT 400 CAN MACHINE 30 FUEL INJECTORS AT THE SAME TIME.

Cavity in a fuel injector with a diameter of four millimeters

DEPENDING ON MATERIAL

Ra 0.05Rz 0.2 /

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Demanding shapes, high-strength materials – even in the most diffi cult circumstances, PECM technology produces excellent results. Take fuel injectors, for example: Precision electro-chemical machining (PECM) not only allows the complex component to be machined with extreme accuracy, but PECM systems like the PT 400 from EMAG also produce extraordinary surface quality, with no burr formation and without changing the material structure. Even highstrength alloys and other challenging materials can be machined with practically no tool wear. In addition, the EMAG tool concept ensures great fl exibility since it is modularly upgradeable when new requirements are faced.

Conclusion: low wear, precise and zero contact. The production of fuel injectors and other complex components benefi ts substantially.

The PT 400 from EMAG The PECM system has a modularly upgradeable tool concept for sophisticated 2D and 3D structures.

The process achieves maximum surface quality even on complex components. In this case, the surface has been set back.

Simple Solution for Complex Applications

PECM TECHNOLOGY

PECM: FIVE CENTRAL BENEFITS

Ability to machine high-strength alloys

Very low tool wear

High repeat accuracy with high surface quality

No burr formation

No impact on the material

1

2

3

4

5

ACCURACY OF THE IMAGE

< 20 μm

FOR EVEN MORE ACCURACY Background of PECM Technology

Electro-chemical machining (ECM) removes metal gently by means of electrolysis, the workpiece becomes the positive anode and the tool becomes the negative cathode. An electrolyte solution fl ows between the two. This removes metal ions from the workpiece.

This process has been perfected in the form of PECM (precision electro-chemical machining). The machining gap is very narrow to ensure that the tools can remove material with even greater precision. In addition, a mechanical oscillation movement helps the electrolyte exchange. This superimposes the feed movement. A pulsed current /voltage source is used to achieve accuracy and a perfect fi nish.

Principle of ECM Technology

Current sourceCurrent sourceCurrent source

CathodeCathodeCathode

WorkpieceWorkpieceWorkpiece

ElectrolyteElectrolyteElectrolyteElectrolyteElectrolyteElectrolyte

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EMAG NEWS 21

Manufacturing Systems for Precision Metal Components

Always keep the Best Production Solution in Sight

MECHANICAL ENGINEERING AT EMAG

How can we drastically improve machining quality and productivity? This is our core competence.That is why we develop production solutions which are tailored to diff erent requirements and ensure top performance, from low cost standard machines to complete manufacturing systems. In doing so, our engineers always keep their focus on the entire production process, not just on the machine itself. The entire process is the target of improvement: machining technology, NC programming, tools, automation and energy consumption.

FROM STANDARD MACHINES TO COMPLETE MANUFACTURING SYSTEMS:EMAG DEVELOPS OPTIMUM SOLUTIONS FOR THE MACHINING OF PRECISION METAL PARTS (PHOTO: MANUFACTURING SYSTEM FOR CAMSHAFTS).

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In many applications, the vertical design and simple automated pick-up system used on EMAG turning machines ensure considerably more effi cient production. Compared to horizontal turning machines this often means:

integrated, reliable automation

high process reliability

automatic workpiece changeover

up to 10 % lower tool wear due to the MINERALIT® polymer concrete machine base

optimum chip fall conditions without chip clusters

good accessibility

also perfect for hard turning processes

integration of several technologies (turning, milling, grinding, gear cutting, and many more)

Vertical Pick-up Machines from EMAG

REDUCING PRODUCTION COSTS

LOWER FLOORSPACE

REQUIREMENT

30 %BY UP TO

30 %LOWER

IDLE TIMESBY UP TO

30 %INCREASED

PRODUCTIVITYBY UP TO

YOUR CONTACTFOR THE COMPLETE MACHINING PROCESS

» Customized production solutions

» From single machines to linked manufacturing systems

» Binding promises for cycle and machining time and for component quality

» Extensive support for (ongoing) production

» Overall responsibility for the production solution

» “ServicePlus” around the clock

» Global sales and service

» Mechanical engineering with the highest quality standards

Substantially reduced production costs – a whole range of design details ensures this fact:

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EMAG NEWS 21

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Manufacturing Systems for Precision Metal Components

EMAGGruppen-Vertriebs- und Service GmbH

SalachAustrasse 2473084 SalachGermanyPhone: +49 7162 17-0Fax: +49 7162 17-820E-mail: info@salach.emag.com

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