EMAG NEWS 25 - EN

EN

25

REINECKER KARSTENS KOPP NAXOS-UNION KOEPFER LASER TEC ECM ELDEC

Manufacturing Systems for Precision Metal Components

VL 3 DUO – TWIN-SPINDLE TURNING MACHINE FOR THE HIGHLY PRODUCTIVE MANUFACTURING OF CHUCKED PARTS EMAG has extended the product range of the extremely successful VL series in the form of the VL 3 DUO, a twin-spindle machine solution for the highly productive manufacturing of chucked parts with a maximum diameter of 150 mm.

The VL 3 Duo design incorporates technological developments from EMAG over the last few years including pick-up and TrackMotion automation systems and modular design.

These advancements are paired to create a highly productive manufacturing system that delivers maximum productivity with the smallest possible footprint.

Access to e-container and hydraulics

Automation belt OP 10

TrackMotion automation system

Spindle 1

Central machining area extraction unit

Automation belt OP 20

Spindle 2

Parts storage unit

19,6 m2*

MINIMAL FLOOR SPACE REQUIREMENT

2

AUTOMATION INCLUDED

PROCESS INTEGRATED MEASUREMENT

On the VL 3 DUO machines, the working spindles are not only used to machine workpieces, but also to load and unload them. This saves money, space and unnecessary peripheral devices.

Optional measuring stations are available outside the machining area, installed between the machining area and the pick-up station. Measurement is carried out during transportation to the loading/ unloading station, thus saving time.

EMAG NEWS 25

HIGH-SPEED MILLING WITH THE VL 3 DUO The VL 3 DUO scores highly in the performance of high-speed milling thanks to its rigid machine design for heavy-duty machining. The combination of high feed forces and large cutting depth allows for the reduction in machining times. ap = 4,75 mm f = 0,4 mm/rev. vc = 250 mm/min

MACHINING AREA OF THE VL 3 DUO: Highly productive for chucked parts with a diameter of 150 mm or less and minimal floor space requirements.

TECHNICAL DATA Max. workpiece diameter

150 mm

Chuck diameter

210 mm

Max. workpiece length

110 mm

Travel distances X (machining stroke) / Y (optional) / Z main spindle (2-piece)

505 / ± 30 / 250 mm

Main Spindle (2-piece) »» Power rating 40% / 100%

18,1 / 13,9 kW

»» Torque 40% / 100%

77 / 59 Nm

»» Max. speed

5.000 1/min

»» Spindle flange to DIN 55026

Größe 6

»» Spindle bearing dia., front

100 mm

Turrets (2x) »» Turret tool pockets (12x)

12 Stk.

Rapid-traverse rate X / Y / Z

60 / 30 / 30 m/min

Very high precision The construction of the machine base with MINERALIT polymer concrete allows vibration damping leading to increased precision. The machine weight is approximately 10,000 kg, with size 45 linear roller guides and direct position measuring systems in all axes.

Integrated automation Pick-up working spindle for loading and unloading

Unique machine concept Two working spindles and two high-performance tool turrets with torque motor

Optimum accessibility Short distance to the turrets and working spindle ensure optimum accessibility Optimum flexibility Parts storage area for up to 400 workpieces* and TrackMotion automation system for high-speed part transport between the parts storage facility and machining areas as well as for turning the workpieces

Minimum floor space requirement 19.6 m2 for the complete machine: VL 3 DUO + TrackMotion + parts storage facility + chip conveyor

Machines are shown in their trade show version. *Fully equipped machine including chip conveyor, TrackMotion and parts storage facility for up to 400 workpieces (depending on the workpiece geometry)

Optimum accessibility also to the TrackMotion automation system

3

Manufacturing Systems for Precision Metal Components

Intermediate gear

THINK VERTICAL: VL PICK-UP TURNING MACHINES The VL Series vertical pick-up turning machines are examples of a new machine concept from the EMAG Group – modular machines.

The VL Series vertical pick-up turning machines were specially developed for manufacturing precision chucked components. Available in four versions, the VL series covers as wide a range of parts as possible ranging from 10 mm to 400 mm.

Machines: VL 2 Sawn part diameter: 60 mm Material: C45 2 OPs

54,6 SEC.

VL SE Workp

Sprocket Machines: VL 2 Material: 16MnCr5 2 OPs

Line cyc

35,4 Sec.

Piston Machine body Z-slide

Machines: VL 4 Sawn part diameter: 100 mm Material: 46S20 2 OPs

X-slide Spindle Measuring system (optional) Turret (optional Y-axis) Automation

X

Z

NOW ALSO WITH SIEMENS SINUMERIK 840D SL

(Y) C Machines are shown in their trade show version.

CUSTOMER: SCHNETO AG ++ Location: Bennwil, Switzerland ++ Requirements: medium to large series, short cycle times for workpieces, hard turning

++ Use of the VL 2: finish turning of semi-

finished workpieces produced on turning machines with bar loaders and end machining of spindles.

Schneto AG specializes in machining turned parts with a diameter of 65 mm of less.

Components for the manufacturing of furniture are part of their extensive portfolio, as are parts for hydraulics and pneumatics, electrical engineering and the automotive and construction industries.

4

Michael Baumann Managing Director at Schneto AG “The space requirement was a major consideration for us. The VL 2 fits into our production system perfectly thanks to its compact design, in spite of the fact that we added a complete automation system for pallet loading the vertical lathe. The machine features very high availability, which we are able to fully take advantage of thanks to the integrated automation system. Using the VL 2 provides us significant benefits in terms of productivity, particularly for workpieces in medium and large batch sizes. The excellent quality of the parts produced on the machine also contributes to these benefits.”

143,4 SEC.

EMAG NEWS 25

Drive gear

154,8 SEC.

Machines: VL 6 Forged part diameter: 220 mm Material: 16MnCr5 2 OPs

THE EMAG TURRET ++ Fast, free of play and wear – The EMAG turret is equipped with a drive unit (torque motor) for the swiveling

Housing

ERIES pieces

cle time

198,6 SEC.

++ Precise – Thermal stability is ensured by

an ambient temperature controlled cooling system

Machines: VL 6 Sawn part diameter: 220 mm Material: 42CrMo4 3 OPs

++ Flexible – The turret has space for twelve tools. Driven tools can be used in all tool stations

Spur gear

212 SEC.

Machines: VL 8 External diameter: 320 mm Material:16MnCr5 2 OPs

0,3 SEC.

TURRET INDEXING TIME

TECHNICAL DATA

VL 2

VL 4

VL 6

VL 8

Max. workpiece diameter

mm

100

200

300

400

Chuck diameter

mm

160

260

400

500

Shortest / longest part

mm

30 / 150

30 / 200

30 / 250

30 / 300

Travel distances: X / Y (optional) / Z

mm

700 / ±50 / 375

740 / ±30 / 400

880 / ±30 / 480

995 / ±30 / 580

»» Power rating 40% / 100% duty cycle

kW

18,1 / 13,9

25 / 18

39 / 28

44 / 34,5

»» Torque 40% / 100% duty cycle

Nm

77 / 59

280 / 202

460 / 340

775 / 600

1/min

6.000

4.500

3.100

2.850

Turret tool positions

Anzahl

12

12

12

12

Rapid-traverse rate X / Y (optional) / Z

m/min

60 / 30 / 30

60 / 15 / 30

60 / 15 / 30

60 / 15 / 30

Revolutions of driven tools

1/min

6.000

6.000

6.000

6.000

Nm

27 / 15

27 / 15

27 / 15

48 / 30

Torque of driven tools 30 % / 100 % ED

++ Vertically designed product families with a modular design

++ Direct position measuring systems are installed in all axes on every VL machines

Main spindle

»» Max. number of revolutions

BENEFITS OF THE VL SERIES

++ Perfect for mass production – from small to large series

++ Our full range of automation and handling technologies are featured on every machine

++ Uniform automation height allows for the simple linking of several machines

++ Suitable for operation of multiple machines

5

Manufacturing Systems for Precision Metal Components

MANUFACTURING SOLUTIONS FOR GEAR WHEELS Modular Machines from EMAG are perfect for the complete production of gearbox components.

The machines always have the same basic structure, with the same transfer height and an automation system designed perfectly to match.

With the modular machine design comes an equally modular automation solution in the TrackMotion system, which was designed with the modular principle in mind.

Whether turning, hobbing or deburring, all machining technologies are available to the user and provide perfect manufacturing results with minimal cycle times.

EMAG MODULAR SYSTEMS Modular production systems by EMAG are characterized by a compact and modular structure. The distance of the machines, the automation transfer heights, the design of the energy container right through to the software interfaces – all of this is standardized and enables the development of production lines in accordance with the modular principle. Thanks to the wide selection of technology modules, the manufacturing systems are individually designed to the customers requirements. Solutions for turning, milling, drilling, gear cutting, chamfering / deburring, laser welding, hardening and grinding are available. With the TrackMotion modular automation system, the diversity of the technologies creates highly productive manufacturing systems for a broad range of applications.

Parts storage unit for up to 400 workpieces including TrackMotion

VL 3 DUO: HIGHLY PRODUCTIVE MANUFACTURING IN JUST 19.6 SQUARE METERS ++ Fast automation: machining OP 10 + OP 20 incl. handling and turning takes only 23 sec.

VL 4 H: FASTEST PICK-UP GEAR HOBBING MACHINE IN THE WORLD

VL 2 RC: EXCELLENT RESULTS IN LINE CY

++ High-speed pick-up gear hobbing machine for milling chu-

++ No moving around of parts, ++ Separate and downstream c

cked parts with a tailstock

++ Excellent chip flow – ideal for high-performance dry gear

ning time delays for gear ho

hobbing

++ From 15 sec. machining time, no machine downtime ++ Up to 400 parts in parts storage unit

++ Measuring probe for post-process measurement with optional process stabilization

++ Tailstock ensures optimum stability and maximum tool

Workpiece diameter / length

6

150 / 110 mm

Module

5-6 sec.

Workpiece diameter / length

Spindle capacity (40% duty cycle)

15,7 kW

Max. angle of inclination

Torque (40 % duty cycle)

Max. module

TECHNICAL DATA

Chip-to-chip time

77 Nm

Max. axial cutting distance

ping

TECHNICAL DATA

service life

TECHNICAL DATA

++ Maximum reduction of seco

Max. workpiece diameter 4 200 / 350 mm

Max. workpiece length Max. feed force

+/- 35°

Ball screw spindle drive

150 mm

Main spindle max. speed

EMAG NEWS 25

Representation of the machines in trade fair version.

Turning for first and second side (OP 10 / OP 20)

T CHAMFERING YCLE TIME chamfering in the line

chamfering and thus no machiobbing

ondary burrs and material war-

Gear hobbing (OP 30)

Roller burring (OP 40)

ELC 160 HP: PRODUCTION LASER WELDING OF RATCHETS

VLC 100 GT: ALWAYS THE OPTIMUM PRECISION MACHINING TECHNOLOGY

++ Complete machining of gear wheels (joining / preheating /

++ Technologies: turning, hard turning, internal grinding,

++ Maximum flexibility thanks to fully automatic retooling

++ Complete machining in a single clamping operation =

++ Highly efficient solid-state laser technology: high efficien-

++ Integrated automation, short distances = short chip-to-

laser welding)

(three fixtures are pre-installed on the machine)

external grinding, circular grinding, non-circular grinding maximum precision.

cy, no protective gas required

chip times.

++ Compact and nevertheless easily accessible design 4

TECHNICAL DATA

200 mm

Workpiece diameter / length

200 mm

Welding diameter

5 kN 32 mm 6.000 1/min

Joining with force/distance monitoring Max. welding clamping force Laser capacity

50–200 / 20–100 mm 20-100 mm 30 kN 5 kN 2,0 - 6,0 kW

TECHNICAL DATA Workpiece diameter / length Main spindle 40 % ED Internal grinding spindle number of revolutions Max. external grinding spindle number of revolutions

100 / 150 mm 15,7 kW / 77 Nm 18.000 – 90.000 1/min 7.200 1/min

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Manufacturing Systems for Precision Metal Components

VLC 200 GT – HARD TURNING, EXTERNAL GRINDING AND INTERNAL GRINDING IN A SINGLE MACHINE Vertical turning and grinding – a combination that has everything.

The VLC 200 GT combines the benefits of vertical hard turning with those of grinding – on a single machine and in a single clamping operation.

BOTH ALUMINIUM OXIDE AND

CBNGRINDING WHEELS

WORKPIECES The VLC 200 GT is specially designed for precise, process-reliable and cost-effective manufacturing in medium- and large-scale production. Typical workpieces machined on the VLC 200 GT include gear wheels, sprocket wheels, sliding sleeves, parts for CVT gears, bearing rings and piston rings.

Gear wheel

Reverse idler gear

Workpiece-Ø: 75 mm Material: 21NiCrMo2

Workpiece-Ø: 68 mm Material: 20MoCr4

38 SEC. VLC 200 GT Workpieces

Ratchet Workpiece -Ø: 146 mm Material: 20MoCr4

52 SEC. 8

59 SEC

Line cycle time

Gear wheel Workpiece-Ø: 60 mm Material: 20CrMoH

56 SEC.

EMAG NEWS 25

THE BENEFITS ++ Reduced machining time: The combination of

hard pre-turning and grinding reduces machining time and produces scroll-free surfaces.

++ Higher workpiece quality and higher pro-

ductivity: In a single clamping operation, the workpiece is hard pre-turned leaving only a few micrometers for the grinding that immediately follows.

++ Minimum grinding wheel wear: Only a little material is cut when grinding. As a result, the grinding wheel is subject to slower wear and needs to be dressed less often, leading to an increase in productivity.

++ Grinding wheels designed for the process:

As only a small allowance needs to be machined due to grinding, the grinding wheels specification is designed specifically for final machined quality. As a result, process reliable surface values can be produced in the area Rz < 1.2 μm.

++ Complete machining in a single clamping

operation: Historically, rear flat surfaces have been difficult to grind due to poor accessibility, with hard turning this problem is eliminated.

++ Use of CBN grinding wheels (optional): CBN grinding wheels can be used to increase productivity and are therefore fitted with a rotating dressing roll to complete the machining task.

TECHNICAL DATA Chuck diameter

210 mm

Swing diameter

270 mm

Max. workpiece diameter

160 mm

Max. workpiece length

100 mm

Travel distances X (total stroke from pick-up to turret) / Z Shuttle automation for supply and removal of parts External grinding spindle Probe Rotating dressing roll Pick-up working spindle

Loading time (depending on clamping device)

1.700 / 250 mm 6 – 10 sec.

Main spindle »» Power rating, 40% / 100% duty cycle »» Torque, 40% / 100% duty cycle »» Max. speed »» Spindle bearing dia., front

22 / 18 kW 250 / 202 Nm 3.000 1/min 110 mm

Internal grinding spindle Turret equipped with 12 tool positions for hard turning tools Numerical control, both Siemens and Fanuc available

Machines are shown in their trade show format.

Automated production using the space-saving EMAG pick-up automation system. As a result, expensive loading portals or other loading devices that may require extensive retooling are not required.

9

Manufacturing Systems for Precision Metal Components

MANUFACTURING SYSTEMS FOR CAM PARTS Customized valve stroke for optimum engine performance – variable valve control with cam parts In the premium automotive segment, valve control using cam parts is now standard.

EMAG's outstanding manufacturing solutions for these central components are anything but standard. EMAG's production line for cam parts is fully-automated, extremely precise and highly productive with a focus on quality.

OP 10

OP 20 / OP 30

OP 20 / OP 30

OP 20 / OP 30

OP 20 / OP 30

OP 60 / OP 70

OP 50

OP 20 + 30: VLC 150 DUO TURNING OF EXTERNAL AND INTERNAL DIAMETERS

OP 60 / OP 70

OP 60 / OP 70

OP 60 + 70: VTC 200 MILLING THE CAMS AND FINISH TURNING THE BEARING DIAMETERS

»» Simultaneous machining of two workpieces using the DUO machine concept

»» Simultaneous 4-axis machining

»» Both turrets are equipped with twelve turning tools

»» Tool turret equipped with turning and milling tools and a workpiece gripper for loading and unloading

»» High availability through use of replacement tools »» Machining of cam part families without retooling is possible »» Probes on each machining side »» Clamping chuck positioned on the upper side of the machine (outside of the clamping area)

10

OP 40

»» High availability through use of replacement tools »» Machining of cam part families without retooling is possible »» Stable tailstock design »» Clamping chuck positioned on upper side of the machine (outside the clamping area)

EMAG NEWS 25

THE WORKPIECES Thanks to the modular plant construction, each manufacturing system by EMAG is perfectly adapted to the workpieces to be machined. The structure of the manufacturing system as a series of machines, each with its unique technology, reduces the number of tools required for each operation. As the turret has a sufficiently large tool storage facility, even entire component families can be machined, virtually without any retooling.

OP 60 / OP 70

OP 80

OP 60 / OP 70

OP 60 / OP 70

OP 100

OP 80

OP 90

OP 80: VTC 250 TWIN MILLING OF SWITCH GROOVES

ADDITIONAL LINE COMPONENTS

»» Simultaneous machining of two workpieces using the TWIN machine concept

»» OP 10: raw parts storage area

»» Both turrets with up to eight milling spindles, probes, workpiece grippers for loading and unloading and a Y-axis for roughing the switch grooves can be upgraded

»» OP 40: DMC labeling

»» High availability through use of replacement tools »» Machining of cam part families without retooling is possible »» Stable tailstock design »» Clamping chuck positioned on upper side of the machine (outside the clamping area)

»» OP 50: internal gear cutting »» OP 90: washing »» OP 100: finished parts storage facility »» Automation cells with robots, workpiece store, SPC and NIO compartment

11

Manufacturing Systems for Precision Metal Components

MANUFACTURING SYSTEMS FROM A SINGLE SOURCE The EMAG Group offers a unique technology portfolio for the production of rotation-symmetric workpieces. By combining these technologies, we offer our customers manufacturing solutions from a single source.

THE BENEFITS: ++ Clear responsibility for the performance of the manufacturing system

++ Reduced expense in planning manufacturing systems ++ Project management with only one accountable party: EMAG

++ Continuous concepts for automation and interlinking ++ Reduced interfaces between facility components offer

OP 60 – VLC 200 Turning

OP 50 – VLC 200 Turning

OP 40 (2) – ELC 160 Ultrasonic testing

increased operational safety

++ A single control and data management concept: prerequisite for Industry 4.0

++ Shortened commissioning for the entire system ++ Standard control concept

VLC 200

++ Simplified maintenance and servicing

»» Machining of chucked parts = standard machine concept »» Small footprint = reduced floor space costs, more possibilities for the machine layout »» Possibility of simple interlinking using automation or central feed and discharge belts and pick-and-place units / changers = flexible in regards to future developments, lower automation costs, and shorter tooling times »» Integrated automation = no additional costs (interfaces, etc.) »» Short transport routes = optimization of idle times »» Common parts strategy, standard storage for replacement parts = low maintenance costs »» Simplified operation (excellent accessibility to machining area) = faster machine set-up »» More economical use of energy = lower electricity costs

BENEFITS OF LASER WELDING ++ By integrating assembly / pressure welding and laser welding, fewer clamping devices and work steps are needed

++ CNC joining presses with integrated process monitoring

++ Tool warping reduced to a minimum due to optimized workpiece handling and clamping

++ Solid-state laser technology does not need protective gas and reduces the heat input

++ Seamless integration of all system components (machine, workpiece handling, laser, automation)

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Laser cleaning

Joining

EMAG NEWS 25

OP 10 - 30 (1) – ELC 160 Laser cleaning, joining and laser welding

ELC 160 »» Production laser welding facility for powertrain components »» Process integration: Joining / pressing with force / distance monitoring, inductive pre-heating, welding, testing »» High precision and reliability through the “fixed optic / moving workpiece” design »» Automatic retooling for optimum flexibility and short changeover time »» Optimum process stability through EMAG clamping and suction technology »» Automatic loading and unloading using loading portal or industrial robots »» Numerous equipment versions and options »» Suitable for CO2 and solid-state laser (disk, fiber) »» SIEMENS SINUMERIK 840 D solution line »» Compact design

Laser welding

Ultrasonic testing

13

Manufacturing Systems for Precision Metal Components

EMAG SFC 600 â&#x20AC;&#x201C; JOINING FREE OF THERMAL FORCES Shaft assemblies and mechanical control assemblies are becoming increasingly important as an alternative to solid components in gearboxes and engines. The benefits of assembled components over conventional solid constructions are essentially significant reductions in weight. In addition, they can have more compact dimensions, a design that better meets demand, greater flexibility in component design and production as well as significantly higher efficiency in managing the range of versions.

The use of assembled camshafts opens up completely new perspectives in engine design. The assembled camshafts contribute significantly to developing fuel-efficient, environmentally-friendly combustion engines.

The patented EMAG process for joining without using thermal forces creates assembled camshafts with optimum precision and minimum effort and expenditure for finishing processes.

THE BENEFITS ++ Lower costs compared to conventional production processes ++ Greater flexibility in production (design of the process chain, shorter retooling times, etc.) ++ The component sequence can be freely selected ++ Angle and axial position can be freely selected ++ Joining precision parts without re-work (for example cams with negative radii) is possible ++ Joining components made of different materials is possible

As a result, the EMAG SFC 600 vertical joining machine becomes the heart of a highly flexible camshaft production process..

Joining parts (cams, sensor wheels, other parts) are supplied on two interchangeable pallets according to position. While the workpieces from the first pallet are automatically removed via a loading portal, the second pallet is already being loaded up.

14

Workpiece recognition using dot patterns or Data Matrix Code (DMC) for workpiece identification and determining the correct position. Transfer to the induction heating station.

EMAG NEWS 25

DE

EN

CN

KR

A powerful eldec induction generator is used in the SFC 600 by EMAG. With its compact design and wide range of control features (optional Profibus / Profinet interface), the eldec medium-frequency generators offer the prerequisites required for integration in entire systems.

SP

IT

Joining process: The pump cam is in the cooling phase at this position. All workpieces are gripped with roll grabs; this ensures maximum thermal insulation, and minimizes the loss of heat energy.

FR More information can be found at: www.eldec.de

RU

Quality inspection of joining results: The probe tests the axial position of the workpiece after the joining process. The prescribed slump is automatically corrected in the case of deviations.

15

Manufacturing Systems for Precision Metal Components

THE VMC SERIES – VERTICAL TURNING / MILLING CENTERS The machines in the VMC MT series are highly flexible production centers with turning and milling spindles positioned at the top.

The focus in the design of the VMC MT series is on universality, allowing them to be configured to suit almost any customer request. The VMC MT series includes a range of tool magazines with up to 80 available tool positions. Various spindle variants complement the range. These features make the VMC MT series the best solution for a wide range of workpieces, while also maintaining top system efficiency. An indexing axis (B) in the milling spindle and a Y-axis in the working spindle are also available. These additional axes allow even complex geometries to be produced using five-sided machining and make the VMC 450-5 MT a genuine high-performance production center for chucked parts.

The machines in the VMC series (with turret) are also available for two-axis and four-axis rotary operation with driven tools.

X

X

B Z

Z

Y

C

C

Arrangement of axes of VMC MT machines: turning / milling spindle and tool magazine, lateral arrangement

TECHNICAL DATA

Arrangement of axes of VMC-5 MT for five-axis machining

VMC 300 MT

VMC 450 / VMC 450 MT

VMC 450-4

VMC 450-5 MT

VMC 600 / VMC 600 MT

mm

315

500

500

500

630

kg

300

300

300

300

500

Swing diameter over base

mm

500

700

700

700

800

Turning diameter, max.

mm

300

450

450

450

600

»» Max. power

kW

48 / 72

48 / 72 / 84 / 106

48 / 72 / 84 / 106

48 / 72 / 84 / 106

72 / 106 / 93

»» Max. torque

Nm

590 / 860

590 / 860 / 1.000 / 1.450

590 / 860 / 1.000 / 1.450

590 / 860 / 1.000 / 1.450

860 / 1.450 / 2.550

»» Max. speed

1/min

3.000 / 2.400

3.000 / 2.400 / 2.000

3.000 / 2.400 / 2.000

3.000 / 2.400 / 2.000

2.400 / 2.000 / 1.250

°

± 0,01

± 0,01

± 0,01

± 0,01

± 0,01

Chuck diameter Weight, max.

Main drive unit

»» Accuracy of spindle positioning

16

EMAG NEWS 25

MACHINING EXAMPLE: PRESSURE PLATE PRODUCTION WITH CBN When pressure plates are machined, very high and robust requirements are set for the machine, due to the material hardness and discontinuous cutting sequence (up to 5 mm cutting depth).

Thanks to the motor spindle with high performance and torque data that is used, machining with full CBN inserts represents a quantum leap and cuts the machining time in half compared to hard metal.

USING CBN TO DOUBLE PRODUCTION

CUSTOMER REQUIREMENTS

++ CBN machining for maximum productivity ++ Very short implementation time ++ Manual loading from the front and robot loading from the side

++ In-process measuring for workpiece and tool ++ Turret with driven tools BENEFITS OF THE EMAG SOLUTION

++ Series solution Machine body Z-slide X-slide Turning / milling spindle Side loading hatch Main spindle Tool magazine, from 36 storage positions

++ Ergonomic manual loading ++ Synchronous spindle motors with direct drive 83 / 54 kW, 990 / 650 Nm

++ Solid spindle bearings with a diameter of 160 mm in tandem O layout

++ C-axis positioning accuracy ±0.01° ++ Free flow of chips around the main spindle RESULTS

++ Doubled production volume when using CBN cutting

COMPARISON OF THE TOOLS USED Cutting edge

Hard metal

Ceramic

CBN

Feed Vc [m/min]

350

800

1.100

Number of revolutions [1/min]

325

740

1.186

Cycle time [min]

2,58

1,65

1,40

116.000

183.000

211.000

Annual production [Pieces/Year]

17

Manufacturing Systems for Precision Metal Components

SALACH Austrasse 24 73084 Salach Germany Phone: +49 7162 17-0 Fax: +49 7162 17-4820 E-mail: info@salach.emag.com

MUNICH Zamdorferstrasse 100 81677 München Germany Phone: +49 89 99886-250 Fax: +49 89 99886-160 E-mail: info@muenchen.emag.com

SWEDEN Glasgatan 19B 73130 Köping Sweden Phone: +46 221 40305 E-mail: info@sweden.emag.com

POLAND ul. Prusa 9F / 1 50-319 Wrocław Poland Phone: +48 728 389 989 Fax: +48 601 371 353 E-mail: info@poland.emag.com

FRANKFURT Martin-Behaim-Strasse 12 63263 Neu-Isenburg Germany Phone: +49 6102 88245-0 Fax: +49 6102 88245-412 E-mail: info@frankfurt.emag.com

AUSTRIA Glaneckerweg 1 5400 Hallein Austria Phone: +43 6245 76023-0 Fax: +43 6245 76023-20 E-mail: info@austria.emag.com

HUNGARY Gerenda u. 10.

1163 Budapest Hungary Phone: +36 30 9362-416 E-mail: lbujaki@emag.com

TURKEY Sanayi Cad. No.: 44 Nish İstanbul Sitesi D Blok D: 155 Yenibosna – Istanbul Turkey Phone: +90 532 694 54 44 E-mail: ckoc@emag.com

LEIPZIG Pittlerstrasse 26 04159 Leipzig Germany Phone: +49 341 4666-0 Fax: +49 341 4666-114 E-mail: info@leipzig.emag.com

DENMARK Horsvangen 31 7120 Vejle Ø Denmark Phone: +45 75 854854 Fax: +45 75 816276 E-mail: info@daenemark.emag.com

CZECH REPUBLIC Lolkova 766 103 00 Praha 10 – Kolovraty Czech Republic Phone: +420 731 476070 E-mail: mdelis@emag.com

FRANCE NODIER EMAG Industrie 2, Parc des Fontenelles 78870 Bailly France Phone: +33 130 8047-70 Fax: +33 130 8047-69 E-mail: info@nodier.emag.com

RUSSIA EMAG OOO ul. Akademika Chelomeya 3/2 117630 Moskau Russia Phone: +7 495 28709-60 Fax: +7 495 28709-62 E-mail: info@russia.emag.com

JAPAN TAKAMAZ EMAG Ltd. 1-8 Asahigaoka Hakusan-City Ishikawa Japan, 924-0004 Japan Phone: +81 76 274-1409 Fax: +81 76 274-8530 E-mail: info@takamaz.emag.com

SPAIN EMAG Máquinas Herramienta S.L. Pasaje Arrahona, no 18 Polígono Industrial Santiga 08210 Barberà del Vallès (Barcelona) Spain Phone: +34 93 7195080 Fax: +34 93 7297107 E-mail: info@emh.emag.com

USA EMAG L.L.C. USA 38800 Grand River Avenue Farmington Hills, MI 48335 USA Phone: +1 248 477-7440 Fax: +1 248 477-7784 E-mail: info@usa.emag.com

BRAZIL EMAG do Brasil Ltda.

Edifício Neo Corporate Offices, CJ 1503 Rua Enxovia, 472 04711-030 São Paulo SP, Brazil Phone: +55 11 38370145 Fax: +55 11 38370145 E-mail: info@brasil.emag.com CHINA – TAICANG EMAG (China) Machinery Co., Ltd Building 3, Cang Neng Europe & American Technology Park No. 8 Lou Jiang Rd. (N.) 215400 Taicang Jiangsu, China Phone: +86 512 5357-4098 Fax: +86 512 5357-5399 E-mail: info@emag-china.com

SOUTH KOREA EMAG Korea Ltd. Rm204, Biz center, SKn Technopark, 124 Sagimakgol-ro, Sangdaewon-dong, Joongwon-gu, Seongnam City Gyeonggi-do, 462-721 South Korea Phone: +82 31 776-4415 Fax: +82 31 776-4419 E-mail: info@korea.emag.com

CHINA – CHONGQING EMAG (Chongqing) Machinery Co., Ltd. No. 10th Lailong Road Yongchuan District 402160 Chongqing China Phone: +86 23 49783399 Fax: +86 23 49783388 E-mail: info@emag-china.com

INDIA EMAG INDIA Pvt. Ltd. Technology Centre, No. 17/G/46-3, Industrial Suburb, 2nd Stage, Yeshwantpur, Bangalore 560022 India Phone: +91 80 42544400 Fax: +91 80 42544440 E-mail: info@india.emag.com

NEWS 25-EN/09.2016 · © Copyright EMAG · Printed in Germany

EMAG Salach GmbH

ITALY ZETA EMAG Srl Viale Longarone 41/A 20080 Zibido S.Giacomo (MI) Italy Phone: +39 02 905942-1 Fax: +39 02 905942-21 E-mail: zetaemag@emag.com GREAT BRITAIN EMAG (UK) Ltd. Chestnut House Kingswood Business Park Holyhead Road, Albrighton Wolverhampton WV7 3AU Great Britain Phone: +44 1902 37609-0 Fax: +44 1902 37609-1 E-mail: info@uk.emag.com

MEXICO EMAG Mexico Maquinaria EMAG Mexico S de RL de CV Av. Hercules 301 Nave 1 Poligono Empresarial Santa Rosa 76220 Santa Rosa Jauregui, Queretar Mexico Phone: +52 (442) 291 1552 E-mail: swieland@emag.com.mx

www.emag.com

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