MANUFACTURING SOLUTIONS FOR MACHINING DIFFERENTIAL HOUSINGS
HIGH POTENTIAL FOR ALL DRIVE CONCEPTS! HIGH-PERFORMANCE
SOLUTIONS FOR THE DIFFERENTIAL HOUSING
for internal combustion engines, electric motors or hybrid engines.
According to a recent study, McKinsey has estimated that global automobile production will grow by approximately two percent annually until 2030. The differential is a perfect example of how these increasing quantities can be tackled effectively despite the high quality requirements. This central component is crucial for all types of drive concept – whether internal combustion engine, electric motor or hybrid engine. Therefore, its production requirements continue to steadily rise. The machining of the differential housing, however, is extremely challenging. For years, the EMAG Group has been working to create the perfect solution.
The EMAG Group has developed a manufacturing solution for the production of differential housings that focuses on maximum productivity and process reliability.
This solution uses machines from EMAG’s modular product range which provide maximum efficiency with a comparatively low investment cost.
OP 10: TURNING THE FLANGE SIDE
The flange side of the housing is machined in OP 10. This is known as the flange side because later the ring gear will be welded to it. The complete internal and external machining of the axle mount takes place in this operation using a bell tool to ensure high-speed machining processes.
Turning the cage side (OP 20) Turning the flange side (OP 10)2
CLAMPING DEVICE: 2 x 2-JAW CLAMPING CHUCK
OP 20: TURNING THE CAGE SIDE
The internal machining of the cage side of the differential housing and the external machining of the axle mount is performed in OP 20 using a bell tool - the borehole is also drilled. To ensure excellent machining quality, customized EMAG chucks are used in both processes and guarantee a secure hold.
OP 30: TURNING THE OUTER DIAMETERS
OP 30 includes the complete external machining of the differential housing. By using a VT 4 for the four-axis machining of the housing, high-quality is guaranteed and machining times are dramatically reduced. Machining in a single clamping operation rules out the possibility of re-clamping errors, and the high rigidity of the two tool turrets and the clamping fixture ensures high tolerances.
OP 40: FINAL MACHINING AND FINISHING
In OP 40, the first thing you see is the impressive clamping device, which was developed by EMAG specifically for the production of differential housings. In this operation, the boreholes are cleaned and the spherical cap is initially scrubbed internally using a banana tool and then dressed.
Turning the external diameters (OP 30)
Final machining and finishing (OP 40)
MANUFACTURING SOLUTIONS FOR MACHINING DIFFERENTIAL HOUSINGS I Manufacturing System for Diff erential Housing Machining
Measuring station NOK parts Cleaning station CYCLE TIME
95 SEC.
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THINK VERTICAL: VL PICK-UP TURNING MACHINES
The vertical pick-up turning machines of the VL-Series are part of the EMAG Group’s Modular Machine line.
The vertical pick-up turning machines in the VL-series were developed specifically for the precision manufacturing of chucked parts. To cover the widest possible range of parts, the VL-series is available in four versions and can machine workpieces ranging from 10 – 400 mm (0.4 – 16 in) in diameter.
MINERALIT® polymer concrete machine base
Z-axis
X-axis
Main spindle
Measuring system (optional)
NOW AVAILABLE:
SIEMENS 840D SOLUTION LINE
Turret with 12 tool positions (optional Y-axis)
Automation
HIGHLIGHTS:
MAXIMUM PRECISION –DIRECT POSITION MEASURING SYSTEMS
THE PATENTED EMAG TURRET
Max. workpiece diameter: 100 mm | 4 in
Max. workpiece length: 150 mm | 6 in
X Z C (Y)
0.3 SEC. TURRET SWIVELING TIME X-AXIS RAPID TRAVERSE RATE 2 mph
4
BENEFITS OF THE VL SERIES:
+ HIGH STRENGTH
Large working spindle bearing diameter + machine body made of MINERALIT®
+ COMPLETE AUTOMATION
Including raw and finished parts storage areas
+ SIMPLE HANDLING
All the service units are easy to reach
+ MINIMUM FOOTPRINT
Compact machine design
+ MAXIMUM PERFORMANCE
Short travel times between the machining area and pickup automation system Machines shown with optional decorative sheet kit
MACHINES
MANUFACTURING SOLUTIONS FOR MACHINING DIFFERENTIAL HOUSINGS I VL Pick-Up Turning Machines Max. workpiece diameter: 200 mm | 8 in Max. workpiece length: 200 mm | 8 in Max. workpiece diameter: 300 mm | 12 in Max. workpiece length: 250 mm | 10 in Max. workpiece diameter: 400 mm | 16 in Max. workpiece length: 300 mm | 12 in TECHNICAL DATA VL 4 VL 6 Max. workpiece diameter mm in 200 8 300 12 Chuck diameter mm in 260 10 400 16 Shortest / longest part mm in 30 / 200 1 / 8 30 / 250 1 / 10 Travel distances, X / Y (optional) / Z mm in 760 / ±30 / 400 29 / ±1 / 16 900 / ±30 / 480 35 / ±1 / 19 Main spindle » Power rating, 40% / 100% duty cycle kW hp 25 / 18 34 / 24 39 / 28 52 / 37 » Torque, 40% / 100% duty cycle Nm ft-lb 280 / 202 206 / 149 460 / 340 339 / 251 » Max. number of revolutions rpm 4,500 3,100 Turret tool positions Quantity 12 12 Rapid-traverse rate, X / Y (optional) / Z m/min ipm 60 / 15 / 30 2,362 / 591 / 1,181 60 / 15 / 30 2,362 / 591 / 1,181 Revolutions of driven tools rpm 6,000 6,000 Torque of driven tools, 30% / 100% duty cycle Nm ft-lb 27 / 15 20 / 11 27 / 15 20 / 11 CLAMPING DEVICE: COLLET CHUCK 5
MAXIMUM PERFORMANCE FOR DIFFERENTIAL PRODUCTION
When it comes to producing a high quantity of differential housings, fast manufacturing processes are crucial. In order to achieve this, the loading and unloading of the machines must be done very quickly. The VT 2 and VT 4 machines guarantee maximum performance with their four axes, short travel distances and powerful main spindle.
The benefits of this machine platform are obvious when the machine is required to produce high part volumes. Since this platform can machine the workpiece from two sides, the production time is dramatically reduced allowing for more parts to be machined, quicker. The machines flexibility is also guaranteed by the two tool turrets, each with eleven tool stations, that can be equipped with turning or driven tools.
TRANSMISSION SHAFT
Example of typical workpieces machined on VT systems.
MINERALIT® polymer concrete machine base
Main spindle
Tool turret 1
Tool turret 2
Control system (Fanuc)
Automation
NOW AVAILABLE:
840D
» Six second workpiece changeover time.
» Comes ready for integration with EMAG TrackMotion automation system.
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SIEMENS
SOLUTION LINE
PRODUCTION
THREE KEY BENEFITS:
+ REDUCED MACHINING TIMES
thanks to four-axis machining
+ SHORTER IDLE TIMES
thanks to simultaneous loading and unloading of components
+ DECREASED INVESTMENT COSTS
thanks to integrated automation
MANUFACTURING SOLUTIONS FOR MACHINING DIFFERENTIAL HOUSINGS I VT Vertical Turning Machines TECHNICAL DATA VT 2 VT 4 Max. workpiece diameter mm in 100 4 200 8 Chuck diameter mm in 160 6 250 10 Swing diameter mm in 210 8 270 10 Workpiece gripper diameter, max. mm in 63 2 133 3 Workpiece length, max. mm in 400 15 630 25 Spindle nose – quill distance mm in 848 33 870 34 » Option: Main and counter spindle / W1 + 100 mm mm in 600 / 700 23 / 27 –» Option: spindle at the bottom mm in 567.5 22 –» Option: tailstock 100 mm (4 in) lower mm in –970 38 » Option: Spindle 160 mm (6 in) higher / 109 mm (4 in) lower mm in –1,030 / 761 40 / 30 Travel distance, X / Y (optional) / Z mm in 332 / ±25 / 625 13 / ±1 / 24 395 / ±25 / 810 15 / ±1 / 32 Main spindle » Power rating, 40% / 100% duty cycle kW hp 21 / 14.1 28 / 19 38 / 29 51 / 39 » Torque, 40% / 100% duty cycle Nm ft-lb 130 / 90 96 / 66 250 / 200 184 / 148 » Max. number of revolutions rpm 6,000 4,500 Turret tool positions 2 x 11 (2 x 1 gripper) 2 x 11 (2 x 1 gripper) Rapid-traverse rate, X / Y / Z m/min ipm 30 / 15 / 30 1,181 / 591 / 1,181 30 / 15 / 30 1,181 / 591 / 1,181 Max. revolutions of driven tools rpm 12,000 9,600 Torque of driven tools, 30% / 100% duty cycle Nm ft-lb 30 / 16 22 / 12 56 / 33 41 / 24 7
AUTOMATED MANUFACTURING –THE KEY TO REDUCING COSTS
On VL machines, the working spindle is used to both machine workpieces and load/unload them. With the customizable carrier prisms, the costs to change parts for different components are extremely low. The carrier prisms are simply inserted in the conveyor belt and the necessary transport-related data is updated on the control unit.
The VT 2 is loaded and unloaded by the turrets. While one workpiece gripper moves a new component into the turning machine, the other removes the finished workpiece. This entire process takes only six seconds.
THE TRACKMOTION AUTOMATION SYSTEM
TrackMotion combines the concept of conveyor belts integrated with gantries into one single automation solution.
The TrackMotion is a track that runs through multiple machines with a TransLift unit attached. The TransLift will grip parts, even parts with different heights, correctly position them and if necessary turn the part over. The way the TrackMotion is set up allows it to link a variety of machines very easily. To decrease cycle times even further, multiple TransLift units can be added.
EXAMPLE: DIFFERENTIAL LINE Raw parts storage area Finished parts storage area NOK parts
8
TRACKMOTION APPLICATION
Track TransLift
TURNKEY LASER WELDING SYSTEM FOR DIFFERENTIAL HOUSINGS
Laser welding is now an established technology for the production of automotive powertrain components. With its technological expertise, EMAG was able to gain an early reputation in this sector as a major systems supplier for customized manufacturing lines for the welding of differentials, differential housing and ring gears.
Currently, the industry is experiencing a technological shift. Vehicles with hybrid drive systems are on the rise, all-wheel-drive vehicles are continuing to improve and the pressure to reduce overall vehicle weight is increasing. These demands all rely on the manufacturer’s ability to produce weight-optimized differential gears that are smaller than those in rear axle differentials on luxury vehicles.
To meet these demands, the ELC 160 from EMAG with an enhanced automation cell is offering an optimized solution for these applications with small differentials. This manufacturing system is setting new industry standards in terms of productivity and economic efficiency.
PERFECT CONNECTION
Precise
THE LATEST INSPECTION EQUIPMENT
Workpieces are checked ultrasonically after each operation to ensure complete process control.
MANUFACTURING SOLUTIONS FOR MACHINING DIFFERENTIAL HOUSINGS I Laser Welding
Machines
with optional decorative sheet metal kit
shown
TECHNICAL DATA ELC 160 Capacity » Workpiece diameter max. mm in 230 9 » NC axes Qty 3 » Fixtures, max. Qty 3 Process modules » Joining with force/distance monitoring » Joining force, max. kN lbf 30 6,744 » Contact force welding, max. kN lbf 5 1,124 9
mechanical engineering and the latest laser technology ensure maximum, uniform quality.
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Turning Milling Grinding Gear Hobbing Power Skiving10
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Heat Shrink Assembly ECM / PECM Laser Welding Induction Hardening
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