2. Manufacturing Systems for Precision Metal Components
High productivity with a minimum floor 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 floor 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 flexible to use.
+ 15 %
+ 30 %
0
20 %
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 Costs
VL 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
first 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 mm
Main drive unit 19.5 kW / 75 Nm 24 kW / 158 Nm 28 kW / 300 Nm 45 kW / 775 Nm
Max. 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
175
160
m2
5
AUTOMATION
USING MINIMUM
FLOOR SPACE
2
3. THE BENEFITS OF THE EMAG VL 2
VERTICAL MACHINING:
SAFE AND EFFICIENT
5
RAPID
PERFORMANCE
Short distances for machining
and loading ensure very short
cycle times.
1
MINIMUM
FLOOR SPACE
REQUIREMENT
The VL 2 takes up only
five square meters.
2
FULL
AUTOMATION
The 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
CONSTRUCTION
The machine body made of
MINERALIT® polymer
concrete ensures high
rigidity and excellent vibration
damping. This directly benefits
the machining quality.
4
SIMPLE
HANDLING
All the service units are freely
accessible, therefore, easy to
reach. Changing tools is also
very simple – just 270 mm
distance to the tool turret.
3
EMAG NEWS 21
4. Manufacturing Systems for Precision Metal Components
VLC 100 G:
Cause and effect
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 flow 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 efficient pro-
duction solution.
Gears, planetary gears, chain wheels and flange 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 floor 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 G
Chuck diameter max.: 160 mm
Machining diameter max.: 100 mm
Grinding length max.: 150 mm
X-axis travel: 650 mm
Z-axis travel: 400 mm
5.7
FOOTPRINT
JUST
m2
UP TO TWO
GRINDING WHEELS IN A
SINGLE MACHINING AREA
4
5. CYCLE TIMES OF ONLY SECONDS – FOUR TYPICAL SUCCESS STORIES
VG 110:
Non-circular grinding
Non-circular operations such as profile
grinding of pump rings
Chuck diameter: 100 – 190 mm
Swing diameter: 125 mm
Machining diameter max.: 60 mm
Workpiece diameter (nominal): 100 mm
X-axis travel: 460 mm
Z-axis travel: 225 mm
VLC 250 DS:
Multi-technology
Turning, hard turning, internal and external
grinding all on a single machine
Chuck diameter: 250 / 315 mm
Swing diameter: 350 mm
Workpiece diameter (nominal): 250 mm
X-axis travel: 1,400 / 1,600 mm
Y-axis travel: ± 100 mm
Z-axis travel: 300 mm
GEAR WHEEL
Machine: VLC 100 G
Technology: internal
circular grinding
Material: 20MnCr5
Cycle time:
22 SeC.
CYLINDER SLEEVE
Machine: VLC 100 G
Technology: internal
circular grinding
Material: 27SiMn
Cycle time:
20 SeC.
PUMP RING
Machine: VG 110
Technology:
non-circular grinding
of internal contour
Material: 100Cr6
Cycle time:
30 SeC.
GEAR WHEEL WITH
INTERNAL POLYGON
Machine: VLC 250 DS
Technology: turning, drilling,
thread tapping and non-circular
grinding of the internal polygon
Material: 16MnCr5
Cycle time:
55 SeC.
22 SeC.
5
EMAG NEWS 21
6. Manufacturing Systems for Precision Metal Components
Large Parts – Massive Efficiency
VLC 500 MT MULTI-TECHNOLOGY CENTERS
MAIN SPINDLE
CAPACITY
FOR FAST
PROCESSES
110kW
6
7. THE 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 flexibility
INTELLIGENT:
Vertical design ‒
ideal downward
chip flow 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 ONCE
One manufacturer uses the VLC 500 MT from EMAG for manufacturing
six different components required for driving the gondola on a
wind turbine. Up to twelve tools are used for this purpose.
Technologies: turning, milling and drilling
Clamping device: EMAG special purpose clamping chuck for all workpiece variants
Materials: cast iron, steel
Workpiece 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 flawless, high speed machining of large components.
The component quality benefits, the process sequence is highly efficient.
Chuck diameter: 500 / 800 mm
Swing diameter: 820 mm
Power rating of main drive unit: 74 / 110 kW
Max. torque: 1,300/ 4,400 Nm
Rapid-traverse rate X / Z: 45/30 m/min
Milling spindle: 40 kW/320 Nm
Tool 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
7
EMAG NEWS 21
8. 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 benefit 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 finished 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 efficient
shaft production. This results in a massive reduction in costs per part.
8
9. Z1
W
X1
A1
C
A2
Y1
Z2
X2
Y2
Productivity comes standard:
» including raw and finished 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 flow 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)
1
SHORT MACHINING
TIMES
» thanks to efficient 4-axis
machining
2
SHORT IDLE
TIMES
» due to simultaneous
loading and unloading
3
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 mm
Main drive unit 19.5 kW / 75 Nm 34 kW / 144 Nm 38 kW / 250 Nm 38 kW / 650 Nm
Max. 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
700
1,000
9
EMAG NEWS 21
10. Manufacturing Systems for Precision Metal Components
More productive
The 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.
Safer
The initial balancing process is
carried out with gap and crash
detection. In addition, process
control benefits from in-process
measurements (external diameter
and longitudinal positioning) on
the component shoulders.
More precise
Absolute 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 efficiently 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 mm
Workpiece length max.: 400 mm
X-axis travel: 360 mm
Z-axis travel: 1,000 mm
COMBINED GRINDING
COMPETENCE
Whether 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 process
In-process measurement of external diameter and longitudinal position
10
11. THE LATEST CBN TECHNOLOGY
IS THE KEY
Even complex shafts can be ground with high precision
(photo, center). CBN grinding wheels are used for cam
profile grinding of camshafts for motorcycles, cars and
trucks (photo, right).
11
EMAG NEWS 21
12. 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 flexible system which is tailored precisely to suit the
specific needs of the customer. Another benefit is that the components can undergo
initial soft milling and hard final machining with guaranteed high quality.
Conclusion: The K 200 gear hobbing machine provides maximum flexibility and
efficient processes.
K 200 GEAR HOBBING MACHINE
Requirements for gear hobbing are rising with a wide
range of components that have to be machined
flexibly 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
12
13. Gear hobbing machine
Module max.
Workpiece diameter mm
Cutting distance mm
Workpiece length mm
Cutting width mm
Shift distance mm
Main spindle speed rpm
Cutter 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 FLEXIBLE
Automation solution for a wide
range of raw parts (manual
loading also possible)
4 UNIVERSAL
Suitable for every hobbing
profile geometry
5 CUSTOMIZED
Many special applications
and machine options available
6
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 finished 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
13
EMAG NEWS 21
14. Laser welding is essential for the production of many automotive
components. EMAG systems provide an extraordinarily efficient
process, including lower energy consumption.
Laser welding is often synonymous with efficient lightweight
construction methods, the weld replaces (heavy) bolt connections and
the components are therefore lighter. To ensure an efficient 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 benefit: 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-efficient 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 different sizes
» Can be fitted with all laser technologies
ELC 160:
Maximum flexibility
» Modular system concept for the production of
medium to large quantities
» Triple-axis NC machining with stationary pro-
cess modules (including optics)
» Can be fitted 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 fitted with all laser technologies
50%
LESS ENERGY
CONSUMPTION
SOLID-STATE LASERS
EMAG is the technology leader in
the use of solid-state lasers for
transmission components. The
efficiency 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
Energy
savings
0
20
40
60
80
KW
100
90
70
50
30
10
Output Cooling capacity
Waste heat
14
15. HIGH SPEED PROCESSES – FOUR APPLICATION EXAMPLES
MINIMUM
DISTORTION
DESPITE HIGH
WELDING SPEED
GEARS
Laser welding a synchronizer
ring to the gear.
Welding / Jointing process time:
i2 Sec.
DIFFERENTIAL HOUSING
Laser welding a ring gear to the
differential housing.
Welding / Jointing process time:
35 Sec.
GEAR SHAFT
Laser welding the synchronizer
wheel to the gear shaft.
Welding / Jointing process time:
I6 Sec.
PROPELLER SHAFT
Assembling the propeller shaft
from three single components.
Welding / Jointing process time:
I4 Sec.
15
EMAG NEWS 21
16. 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 efficiency 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
Ra0.05
Rz0.2/
16
17. Demanding shapes, high-strength materials – even in the most difficult 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 flexibility 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 benefits 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
<20μm
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 flows 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 finish.
Principle of ECM Technology
Current source
Current source
Current source
Cathode
Cathode
Cathode
Workpiece
Workpiece
Workpiece
Electrolyte
Electrolyte
Electrolyte
Electrolyte
Electrolyte
Electrolyte
17
EMAG NEWS 21
18. 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 different 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).
18
19. In many applications, the vertical design and simple automated pick-up
system used on EMAG turning machines ensure considerably more
efficient 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 TIMES
BY UP TO
30%
INCREASED
PRODUCTIVITY
BY UP TO
YOUR CONTACT
FOR 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:
19
EMAG NEWS 21