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MODULAR MACHINES FROM THE EMAG GROUP


PICK-UP TURNING MACHINES FOR CHUCKED PARTS The VL Series vertical pick-up turning machines are examples of the modular standard platform from the EMAG Group. The VL series vertical pick-up turning machines were developed for the manufacturing of precision chucked parts. To cover as wide a range of parts as possible, the VL Series is available in four versions with workpiece diameters ranging from 0.4 to 15.7 inches. Machine Body Z-Axis X-Axis Spindle Measuring System (optional) Turret (optional Y-axis) Automation

X

Z

(Y) C

0.3 SEC.

TURRET INDEXING TIME

RAPID TRAVERSE RATE X-AXIS

196 FT/MIN

HIGH PRECISION – THE PATENTED DIRECT POSITION MEASURING SYSTEMS EMAG TURRET ++ Glass scales – Fully encapsulated linear

++ Fast, wear free – the EMAG turret is equipped with a drive unit

++ Standard – Glass scales come standard

++ Precise – Thermal stability is ensured thanks to an ambient

glass scales in all linear axes on all EMAG machines!

(torque motor) for swiveling.

temperature controlled cooling system.

++ Flexible – The turret has space for twelve tools (featuring either a VDI or BMT). Driven tools can be used in all tool stations as an option. Chose to add a Y-axis to ensure maximum flexibility.

2


THE VL PLATFORM I VL 2, VL 4, VL 6, VL 8

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

Machines shown with optional decorative sheet kit

Short distances between the machining area and pick-up automation system

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VL MACHINES IN OPERATION VL 2 and VL 4 for Small and Medium-Sized Workpieces The VL 2 and VL 4 pick-up turning machines are ideal for workpieces with a diameter of up to 4 / 8 in. The machines feature an integrated automation system and a parts storage area that allows them to operate completely autonomously, relieving the strain on production personnel. Efficient mass production of various batch sizes is possible with these machines and, thanks to their flexible clamping systems, they can also machine entire part families without any problem.

SIEMENS 840D SL AVAILABLE

Intermediate Gear

Machine: VL 2 Sawn part diameter: 2 in Material: C45 2 OPs

Cover

Machine: VL 2 Sawn part diameter: 4 in Material: X5CrNi1810 2 OPs

Machine: VL 4 Forged part diameter: 5 in Material: 16MnCr5 2 OPs

4

Machine: VL 2 Pre-forged part diameter: 2 in Material: 16MnCr5 2 OPs

VL 2 / VL 4 Workpieces

101 SEC.

Main Hub

Sprocket

55 SEC. 35 SEC.

Line cycle time

100 SEC.

143 SEC.

Piston

Machine: VL 4 Sawn part diameter: 4 in Material: 46S20 2 OPs


DIE VL-PLATTFORM THE VL PLATFORM I I VL VL62,+ VL VL 4, 8 VL 6, VL 8

VL 6 and VL 8 for Large Workpieces If you want to machine larger workpieces productively or are striving for maximum flexibility in production, look no further than the VL 6 and VL 8 pick-up turning m ­ achines. The integrated conveyor belt makes loading the m ­ achines with heavy parts a breeze; the parts are simply placed on the conveyor belt by crane and the m ­ achine takes care of the rest.

Spur Gear

Machine: VL 8 External diameter: 12 in Material: 16MnCr5 2 OPs

212 SEC. Drive Gear

Machine: VL 6 Sawn part diameter: 9 in Material: 42CrMo4 3 OPs

Line cycle time

155 SEC.

TECHNICAL DATA

Housing

VL 6 / VL 8 Workpieces

Machine: VL 6 Forged part diameter: 9 in Material: 16MnCr5 2 OPs

199 SEC.

VL 2

VL 4

VL 6

4

8

12

100

200

300

VL 8

400

Workpiece diameter, max.

mm

Chuck diameter

mm

160

260

400

500

Workpiece length, max.

mm

150

200

250

300

Travel distances X / Y (optional) / Z

mm

650 / ± 50 / 375

760 / ± 30 / 415

900 / ± 30 / 495

1,110 / ± 30 / 595

»»Power rating, 40% / 100%

kW

18 / 14

25 / 18

39 / 28

44 / 34,5

»»Torque, 40% / 100%

Nm

77 / 59

280 / 202

460 / 340

775 / 600

rpm

6,000

4,500

3,100

2,850

Main spindle

»»Max. number of revolutions Turret »»Turret tool positions »»Revolutions of driven tools »»Torque of driven tools at 30% / 100% duty cycle Rapid-traverse rate X / Y / Z

inch inch inch inch

hp

ft-lb

6 6

27 / ±2 / 15

24 / 19

57 / 44

10 8

30 / ± 1 / 16

36 / 24

223 / 149

15

10

35 / ± 1 / 19

52 / 38

339 / 251

15

19 12

43 / ± 1 / 23

59 / 46

572 / 443

Quantity

12

12

12

12

rpm

6,000

6,000

6,000

6,000

Nm

27 / 15

27 / 15

27 / 15

48 / 30

m/min

60 / 30 / 30

60 / 15 / 30

60 / 15 / 30

60 / 15 / 30

ft-lb

ipm

20 / 11

2,363 / 1,181 / 1,181

20 / 11

2,363 / 591 / 1,181

20 / 11

2,363 / 591 / 1,181

35 / 22

2,363 / 591 / 1,181

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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 it can link a variety of machines very easily. To decrease cycle times even further, multiple TransLift units can be added.

The raw components are supplied by a parts storage area. This has a capacity to hold up to 400 parts, depending on the geometry of the workpiece.

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From small to large with no retooling. The universal NC gripper ensures that the ­machine can be reset very quickly.


PERFECT SYMBIOSIS: MODULAR MACHINES AND TRACKMOTION AUTOMATION SYSTEMS

Benefits ++ Customized for the modular machines ++ Replaces belts, pick-and-place units and changers

++ Allows stackable pallets to be used (large parts buffer)

Machines are shown with optional decorative sheet metal kit

The design of the modular machines includes a tunnel immediately behind the machining area, created using the separate energy container. The track is then installed in this tunnel and includes the NC gripper (TransLift) to transport parts. To facilitate picking up and positioning the parts on stackable pallets, the gripper system also has a Z axis. By using three different axes to position the parts, an extremely high number of raw workpieces and finished parts can be stored in a very small space (up to 400). This automation system can also turn the parts between operations, replacing traditional systems such as belts, pick-and-place units and changers.

Linking two VL 2 turning machines to a VL 4 H gear hobbing machine using the EMAG TrackMotion automation system (shown without safety fences)

THE VL PLATFORM I Automating the VL Series

On the VL machines, the working spindle is not only used to ­machine workpieces, but also to load and unload them. Thanks to carrier prisms, the costs to change parts are extremely low. The prisms are simply installed onto the conveyor belt and the transport-related data are entered in the control unit.

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TECHNICAL DATA MACHINES

VL 2

VL 4

VL 6

4

8

12

VL 8

Workpiece diameter, max.

mm

Chuck diameter

mm

160

260

400

500

Swing diameter

mm

210

280

420

520

Shortest / longest part

mm

30 / 150

30 / 200

30 / 250

30 / 300

Workpiece weight

kg

5

20

40

Weight, max.: clamping device + clamping cylinder + workpiece + draw bar Turret

kg

inch inch inch inch lb

100 6 8

1/6

11

200 10 11

1/8

44

300 15 16

1 / 10

88

400 15 19 20

1 / 12

60

132

lb

189

86

150

300 661

1,543

Quantity mm

12 710 / 610 (with Y)

12 860

12 920

12 1,000

mm

330

360

360 / 380

440

VDI 30 / BMT 55

VDI 40 / BMT 55

VDI 40 / BMT 65

VDI 50 / BMT 75

»» Torque of driven tools, 30% / 100% duty cycle

rpm Nm

6,000 27 / 15

6,000 27 / 15

6,000 27 / 15

6,000 48 / 30

»» Tool length, max.

mm

190 / 140

250

280

280

s

0.8

0.9

1.0

1.1

»» X stroke, turning only / with loading

mm

295 / 650

290 / 760

330 / 880

380 / 995

»» Y stroke

mm

±50

±30

±30

±30

»» Z stroke

mm

»» Turret tool positions »» Turret cutting circle »» Turret width across flats »» Tool connection »» Revolutions of driven tools

»» Turret indexing time for one position (30°) Travel distances

Rapid traverse [acceleration]

inch inch

ft-lb

inch

inch

inch inch

»» X

m/min, [m/s²]

»» Y (optional)

m/min, [m/s²]

»» Z

m/min, [m/s²]

Feed pressure X / Y (optional) / Z

28 / 24 (with Y)

13

20 / 11 7/5

11 / 25

±2

375 15

60, [4]

331

34 14

20 / 11

10

11 / 30

±1

415 16

60, [4]

36

14 / 15

20 / 11

11

13 / 34

±1

495 19

60, [4]

700

39 17

35 / 22

11

15 / 39

±1

595 23

60, [4]

ipm, [ft/s²]

2,363 [13]

2,363 [13]

2,363 [13]

2,363 [13]

ipm, [ft/s²]

1,181 [13]

591 [13]

591 [13]

591 [13]

ipm, [ft/s²]

1,181 [13]

1,181 [13]

1,181 [13]

1,181 [13]

kN

30, [4] 30, [4]

2.5 / 5 / 13.7

15, [4] 30, [4]

6.9 / 7.5 / 18.7

15, [4] 30, [4]

6.9 / 7.5 / 18.7

15, [4] 30, [4]

9,3 / 12 / 12.5

lbf

562 / 1,124 / 3,080

1,551 / 1,686 / 4,204

1,551 / 1,686 / 4,204

2,091 / 2,698 / 2,810 2 / 1.6 / 2

Ball screw dia. X / Y / Z

mm

inch

1.3 / 1.3 / 1.6

1.6 / 1.6 / 1.6

1.6 / 1.6 / 1.6

Linear guides

Size

35

45

45

55

Size dia. in mm

A5 80

A6 110

A8 140

A11 160

s

5–6

7–8

8–9

10–12

»» 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

»» Full power at speed of

rpm

2,250

850

800

550

»» Max. number of revolutions

rpm

6,000

32 / 32 / 40

40 / 40 / 40

40 / 40 / 40

50 / 40 / 50

Working spindles »» Spindle nose (DIN 55026) »» Spindle bearing »» Loading time (depending on clamping device) Main spindle, standard version

8

Ø in inch

hp

ft-lb

3

24 / 19

57 / 44

2,250 6,000

4

34 / 24

207 / 149 850

4,500 4,500

5

52 / 38

339 / 251 800

3,100 3,100

6

59 / 46

572 / 443 550

2,850 2,850


Machine dimensions

VL 2

VL 4

VL 6

VL 8

»» Width A

mm

1,600

1,254

1,850

2,120

»» Width B

mm

1,870

2,320

2,260

2,620

»» Length C

mm

720

590

700

720

»» Length D

mm

2,970

3,440

3,900

4,000

»» Length E

mm

4,800

5,368

5,900

6,500

»» Length F

mm

6,550

7,870

7,700

8,300

»» Length G

mm

1,750

2,500

1,800

1,800

»» Height H

mm

1,000

1,000

1,000

1,000

»» Height I

mm

2,525

2,525

2,525

2,525

»» Height J

mm

3,100

3,600

3,600

3,500

»» Height K

mm

325

325

325

325

»» Height L

mm

800

800

800

800

kg

6,000

8,000

10,000

12,000

inch

63

inch

73

inch

141

13

31

lb

99

141

13

inch

39

99

122

inch

71

39

99

inch

303

98

39

inch

232

310

69

inch

153

211

258

inch

27

135

189

inch

89

23

117

inch

73

91

28

inch

Weight

49

13

31

13,228

31

12,787

12,787

83

103 28

157 256 327 71

39

99

138 13 31

THE VL PLATFORM I Specifications of the VL Series

MACHINES

26,455

A

C

D

E

F

G

K

H

L

I

J

D

B

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VL 1 TWIN – HIGHLY PRODUCTIVE SIMULTANEOUS M Twin-spindle turning center for the highly productive manufacturing of workpieces up to 75 mm (3 in) in diameter The VL 1 TWIN has two main spindles in one machining area which can simultaneously machine two identical workpieces. This method allows for a massive increase in output quantities and lowers cost per piece.

HIGH SPEED LINEAR MOTOR

The diameter and length (X / Z direction) of both components can be corrected independently of one another using both spindles. In addition, the machine has a direct position measuring system and a linear motor in the X-axis to ensure the highest machining quality and maximum productivity.

TECHNICAL DATA Max. workpiece diameter

mm

75

Chuck diameter

mm

140

Swing diameter

mm

160

Workpiece length, max.

mm

75

kg

1

X-axis / Z-axis travel

mm

605 / 200

Main spindle »» Power rating, 40% / 100% duty cycle

kW

Workpiece weight

»» Torque, 40% / 100% duty cycle »» Max. number of revolutions Rapid-traverse rate, X / Z Tool stations CNC controller

10

inch inch inch inch lb

inch

hp

Nm ft-lb

rpm m/min ipm

3 5

Planetary gear

6

Workpiece dia: 2 in Material: 20CrMoH

3

Sleeve

Workpiece dia: 2 in Material: 21NiCrMo2

2

10 / 9

13 / 12

136 / 95

100 / 70

6,000 60 / 30

2,400 / 1,200

2 x 4 – VDI30 / BMT45 Fanuc 31i with Manual Guide i

16 SEC.

12 SEC.

23 / 8

Flange Workpiece dia: 2 in Material: CrNi1810

26 SEC.

VL 1 TWIN Workpieces Cycle Time*

Cam

Workpiece dia: 2 in Material: 100Cr6

9 SEC.


MACHINING Highlights

++ Maximum precision

Machine base made of MINERALIT® with optimal vibration-damping properties, size 45 linear roller guides as well as direct position measuring system in the X-axis for the highest positioning accuracy, repeat accuracy and long-term accuracy.

++ Integrated automation

Two pick-up working spindles for loading and unloading. “Automation ready”: Linking with other EMAG machines / technologies (e.g., gear hobbing) possible thanks to TrackMotion automation system.

THE VL PLATFORM I The VL 1 TWIN

SIMULTANEOUS MACHINING

++ Unique TWIN concept

Simultaneous machining of two identical workpieces is possible, which means doubling the output and reducing the cost per piece. Diameter and length (X / Z direction) of both components can be adjusted independently of one another.

++ Maximum dynamics

Linear drive in the X-axis for maximum dynamics, minimal wear and maximum positioning accuracy.

AUTOMATION INCLUDED

On the VL 1 TWIN 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. Linking two VL 1 TWIN machines including parts storage area and TrackMotion automation system Access to e-container and hydraulics

Number of spindles

Machine 1 (OP 10 / OP 10)

Access to e-container and hydraulics

TrackMotion automation system

Number of spindles

Machine 2 (OP 20 / OP 20)

Parts storage area

* Cycle time of 9 sec., for example, for a machining time of 18 sec. (2 spindles)

FULLY INTEGRATED MEASURING SYSTEM

Measuring systems installed between the machining area and the pick-up station are available as an option. To save time, these measurements are performed during the parts’ movement to and from the loading/ unloading station.

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TWIN-SPINDLE TURNING MACHINE FOR THE HIGHLY OF CHUCKED PARTS EMAG has extended the VL series product range with the VL 3 DUO, a twin-spindle machine solution for the highly productive manufacturing of chucked parts up to 6 inches in diameter. The VL 3 DUO integrates all of the most recent EMAG technological developments (including pick-up automation, the TrackMotion automation system and the modular design of the machine) to create a highly productive manufacturing system that delivers maximum productivity with a minimum footprint.

Access to E-Container and Hydraulics OP 10 NC Shuttle TrackMotion Automation System

Spindle 1

Central Machining Area Extraction Unit OP 20 NC Shuttle

Spindle 2

Parts Storage Area

SIEMENS 840D SL AVAILABLE

HIGH-PERFORMANCE TURNING WITH THE VL 3 DUO The VL 3 DUO is perfect for heavy-duty machining thanks to its rigid machine design. High feed forces with a large cutting depth allows for the reduction of machining time. Standard Spindle: ap =

4.75 mm

f =

0.4 mm/rev

vc =

0.2 in

0.02 in/rev

250 m/min

1,000 in/min

High Torque Spindle:

12

ap =

8.5 mm

f =

0.4 mm/rev

vc =

250 m/min

0.3 in

0.02 in/rev

1,000 in/min

*Fully equipped machine includes chip conveyo


Y PRODUCTIVE MANUFACTURING

HIGH TORQUE SPINDLE WITH A 32 KW CAPACITY

VL 3 DUO FOR DEMANDING TURNING WORK

++ Working spindle with 5,000 rpm / 32 kW / 255 Nm at 40% duty cycle

++ Sturdy mechanical design – Spindle bearing, front:

4 in. diameter, Spindle flange to DIN 55 026, size 6

++ Motor spindle with DirectDrive to minimize run times, maximize true running and diameter tolerances

++ Maximum torque over a large range of speeds –

MACHINING AREA OF THE VL 3 DUO:

baseline spindle speed: 1,408 rpm (at 100% duty cycle)

THE VL PLATFORM I The VL 3 DUO

NEW!

++ Water-cooled motor spindle for maximum thermal

Highly productive machining for chucked parts with a maximum diameter of 6 inches.

stability

196 175 150 125 100 75 50

35 30 25 20 15 10

25

Precise Machining

Machine base made of MINERALIT® polymer concrete, machine weight 22,046 lbs, 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

Increased Flexibility

Parts storage area for up to 400 workpieces and TrackMotion automation system for high-speed part transport between the parts storage area and machining areas as well as for turning the workpieces

Minimum Floor Space Required

264 ft for the complete machine: VL 3 DUO + TrackMotion + parts storage area + chip conveyor 2

Machines shown in trade show format.

or, TrackMotion and parts storage area for up to 400 workpieces (depending on the workpiece geometry)

Torque (Nm) 40% duty cycle

Power rating (KW)

Number of revolutions (1/min)

40% duty cycle

100% duty cycle

TECHNICAL DATA

5,400

4,800

4,200

3,600

3,000

2,400

1,213 1,408 1,800

600

5 6,000

Torque (Nm)

225

Power rating (KW)

50 45 40

255

100% duty cycle

Workpiece diameter, max.

mm

150

Chuck diameter, max.

mm

210

Workpiece length, max.

mm

110

Travel distance: X (machining stroke) / Y (optional) / Z Main spindles (2x) – Standard

mm

505 / ±30 / 250

»» Power rating, 40% / 100%

kW

17.9 / 15.5

»» Torque, 40% / 100%

Nm

144 / 98

»» Max. number of revolutions »» Spindle flange to DIN 55026

rpm Size mm

5,000 6 100

»» Spindle bearing dia., front High Torque Spindle – Option

inch inch inch inch

hp

ft-lb

inch

6 8 4

20 / ±1 / 10

24 / 21

106 / 72

4

»» Power rating, 40% / 100%

kW

32.4 / 28.9

»» Torque, 40% / 100%

Nm

255 / 196

rpm

5,000

»» Max. number of revolutions Turrets (2x) »» Turret tool positions Rapid-traverse rate X / Y / Z

hp

ft-lb

Qty m/min

43 / 38

188 / 144

12 60 / 30 / 30

ipm 2,362 / 1,181 / 1,181

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TECHNICAL DATA MACHINE

150

Workpiece diameter, max. Chuck diameter

mm

210

Swing diameter

mm

250

Workpiece length, max.

mm

110

Workpiece weight

kg

10

Weight, max.: clamping device + clamping cylinder + workpiece + draw bar Turrets (2x) »»Turret tool positions

kg

145

Quantity mm

12 720

mm

360

-

VDI 40 / BMT 55

rpm Nm

5,000 27 / 15

»»X stroke, turning only / with loading

mm

180 / 505

»»Y stroke

mm

±30

»»Z stroke

mm

»»Turret cutting circle »»Turret width across flats »»Tool connection »»Revolutions of driven tools »»Torque of driven tools, 30% / 100% duty cycle Travel distances

Rapid traverse [acceleration]

inch inch inch

inch

lb lb

inch inch

ft-lb

inch inch

inch

»»X

m/min, [m/s²]

»»Y (optional)

m/min, [m/s²]

»»Z

m/min, [m/s²]

Feed pressure X / Y (optional) / Z Ball screw dia. X / Y / Z Working spindles

6 8

10 4

22

319

28 14

20 / 11

7 / 20 ±1

250 10

60, [4]

ipm, [ft/s²]

2,363 [13]

ipm, [ft/s²]

1,181 [13]

ipm, [ft/s²]

1,181 [13]

kN

30, [4] 30, [4]

6/5/8

lbf

1,349 / 1,124 / 1,798

inch

1.6 / 1.3 / 1.6

mm

40 / 32 / 40

Diameter in mm

100

»»Power rating, 40% / 100% duty cycle

kW

17.9 / 15.5

»»Torque, 40% / 100% duty cycle

Nm

144 / 98

»»Full power at speed of

rpm

1,509

»»Max. number of revolutions

rpm

5,000 32,4 / 28,9

»»Torque, 40% / 100% duty cycle

kW hp Nm

»»Full power at speed of

rpm

1,400

»»Max. number of revolutions

rpm

5,000

»»Spindle bearing Main spindle, standard version

Main spindle, high performance version »»Power rating, 40% / 100% duty cycle

14

VL 3 DUO

mm

Ø in inch

hp

ft-lb

ft-lb

4

24 / 21

106 / 72

42 / 38

255 / 192

105 / 66


VL 3 DUO

Machine dimensions »»Width A

mm

2,200

»»Width B

mm

4,200

»»Length C

mm

4,831

»»Length D

mm

3,112

»»Height E

mm

325

»»Height F

mm

2,525

inch

86

inch

165

inch

190

inch

122

inch

256

inch

327

THE VL PLATFORM I The VL 3 DUO

MACHINE

B D

C

E

F

A

15


HEAVY-DUTY MACHINING OF COMPLEX WORKPIECES The VM 9 vertical turning center is designed for the production of individual parts or small/medium production runs with a wide variety of parts. The machines tool turret has twelve tool positions, and depending on the interface desired by the customer (BMT or VDI), the turret can be equipped with driven tools. This allows for additional manufacturing flexibility as the machine can be equipped for a variety of things, for example drilling operations. Based on customer requirements, the workpieces can either be loaded manually using a crane, or automatically through the side loading door. In order to guarantee consistently high workpiece quality, the machine has an integrated probe installed (first part = good part). With all of these features included, the VM 9 is extremely well equipped for a wide variety of production tasks.

Machine Body Z-Axis X-Axis Spindle Main Spindle Control Panel

X

Z

WORKING SPINDLE WITH UP TO

83 KW FULL POWER

16

C


VERTICAL TURNING CENTERS I VM 9

++ MAXIMUM PRODUCTIVITY: Highly dynamic axes for short idle times and quick machining processes

++ SIMPLE HANDLING: All the service units are easy to reach ++ AUTOMATION CONCEPT (OPTIONAL): Loading through

the side loading hatch with a gantry or robot. Direct access to the machining area through the separate front door

++ MAXIMUM PERFORMANCE: Thanks to short transport distances

++ HIGH SURFACE ACCURACY: Axis monitoring by rotary,

indirect absolute encoders or with a fully encapsulated linear glass scale (optional)

++ IDEAL FOR HEAVY-DUTY MACHINING: Generously

­ imensioned main spindle, maintenance-free spindle motors d and rigid guideways

++ VERY LONG WORKPIECE SERVICE LIVES:

Very rigid machine body made of MINERALIT®, six to eight times better damping properties than gray cast iron

TECHNICAL DATA

mm

450

kg

300

Swing diameter over base

mm

650

Turning diameter, max.

mm

450

X-axis / Z-axis travel

mm

330 / 500

Spindle height (without clamping devices)

mm

970

Chuck diameter Weight, max.

»» Spindle bearing Main drive unit »» Synchronous motor 40% duty cycle / 100% duty cycle »» Full power at speed of »» Torque 40% duty cycle / 100% duty cycle »» Max. number of revolutions »» Spindle positioning accuracy (C-axis) Feed drive »» Rapid-traverse rate X / Z »» Feed force X / Z »» Ball screw dia. X / Z Disk-type turret »» for cylindrical shanks to DIN 69 880 »» Turret tool positions

lb

inch inch inch

inch

18

661 25 18

13 /19 38

Size mm

8 140 / 160

kW

49/83 / 32/54

inch

hp

5/6

66/111 / 43/74

rpm 800 Nm 585/990 / 380/650 ft-lb

rpm °

m/min

431/730 / 280/479

3,000 / 2,400 ±0.01 30 / 30

ipm

1,181 / 1,181

lbf

899 / 1,798

inch

1/1

kN

mm

4/8

40 / 40

»» Width across flats

mm

VDI 40 / BMT 65 8 / 12 360 / 380

»» Cutting circle

mm

690

»» Torque of driven tools, 40 % / 100%

Nm

24 / 15

rpm

6,000

»» Revolutions of driven tools

inch

inch

ft-lbh

Machines shown with optional decorative sheet metal kit

Main spindle »» Spindle flange to ISO 702-1: 2009

inch

15 / 15

27

20 / 11

17


VL 4 H VERTICAL PICK-UP GEAR HOBBING MACHINE The VL 4 H Machines Geared Components up to 8 Inches in Diameter and Module 4. The modular VL 4 hobbing machine is equipped with the EMAG standard pick-up concept, and is loaded/ unloaded by the working spindle. Its compact design, short transport distances and highly dynamic axes ensure short idle times, making the VL 4 H a highly productive gear hobbing machine.

Machine Body

Measuring System (Optional)

Gear Hobbing Head Spindle Control System (Fanuc) Automation

In the pick-up station, the parts on the conveyor belt are centered using the NC p ­ rogram, eliminating clamping errors.

18


Standard module, max.

VERTICAL PICK-UP GEAR HOBBING MACHINE I VL 4 H

TECHNICAL DATA 4

Workpiece diameter, max.

mm

200

Workpiece length, max.

mm

350

Axial cutting distance, max.

mm

150

X-axis travel (radial infeed)

mm

115

Z-axis travel (main spindle)

mm

400

»» Power rating, 100% duty cycle

kW

22

»» Torque, 100% duty cycle

Nm

140

»» Full power at speed of »» Max. number of revolutions

rpm rpm

1,500 2,000

»» Tool diameter, max.

° mm

±35 100

»» Tool length (gearing length), max.

mm

240

»» Shift travel

mm

200

»» rpm range, max. »» Motor capacity, 100% duty cycle

rpm kW

3,000 28

»» Torque (100% duty cycle)

Nm

140

inch

inch inch

inch inch

8

14 6 4

15

Main spindle

Gear hobbing head »» Swivel angle, max.

hp

ft-lb

inch inch

inch

hp

ft-lbh

30

103

4

9 8

38

103

Machines shown with optional decorative sheet metal kit

The integrated “O” automation allows the machine to be loaded and unloaded easily.

The CHAMFER CUT method developed by FETTE is ideal for the precise and cost-effective chamfering processes for wheel-shaped workpieces because this method produces no secondary burrs.

19


HIGH PERFORMANCE SHAFT PRODUCTION When it comes to producing a high quantity of shafts, fast manufacturing processes are crucial. In order to achieve this, the loading and unloading of the machine 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 spindles. 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.

SIEMENS 840D SL NOW AVAILABLE Turret 1 Working Spindle with C-Axis Turret 2 Tailstock Automation

THE BENEFITS ++ NEW! The standard machine now

comes prepared for integration with the TrackMotion automation system.

++ Reduced machining times due to four-axis machining

++ Shorter idle times with simultaneous

loading and unloading of components

++ Lower investment costs thanks to integrated automation

AUTOMATION SEQUENCE The gripper in turret 1 takes a workpiece from the raw parts storage area and transports it to the main spindle/tailstock. At the same time, the gripper in turret 2 takes the machined workpiece from the main spindle/tailstock and transports it to the finished parts storage area.

20


VERTICAL SHAFT TURNING MACHINES I The VT Series

THREE KEY FACTORS ++ REDUCED MACHINING TIMES due to four-axis machining

++ SHORTER IDLE TIMES

thanks to simultaneous loading and unloading of ­components

++ HIGHLY PRODUCTIVE SHAFT MANUFACTURING thanks to integrated automation

6

SEC.

WORKPIECE CHANGEOVER TIME

TECHNICAL DATA

VT 2

VT 4

Chuck diameter

mm

Swing diameter

mm

210

270

Workpiece diameter, max.

mm

100

200

Workpiece gripper diameter, max.

mm

63

90

Workpiece length, max.

mm

400

630

X-axis travel

mm

336

395

Z-axis travel

mm

625

810

Y-axis travel (optional)

mm

± 25

± 25

»» Power rating, 40% / 100%

kW

34 / 26.5

38 / 29

»» Torque, 40% / 100%

Nm

144 / 112

250 / 200

»» Max. number of revolutions

rpm

6,000 2 x 11

4,500 2 x 11

inch

inch

inch inch inch inch inch

6 8 4 2

15 13 24

±1

260 10 10 8

3

25

15 32

±1

Main spindle hp

ft-lb

Turret tool positions Workpiece diameter, max.: 4 inches

Workpiece diameter, max.: 8 inches

Workpiece length, max.: 16 inches

Workpiece length, max.: 25 inches

Rapid-traverse rate X / Y / Z Max. revolutions of driven tools Torque of driven tools 25% / 100%

46 / 36

106 / 83

51 / 39

Machines shown with optional decorative metal skirt kit

inch

160

184 / 148

(2 x 1 gripper)

(2 x 1 gripper)

m/min

30 / 15 / 30

30 / 15 / 30

rpm Nm

6,000 24 / 12

6,000 30 / 15

ipm 1,181 / 591 / 1,181 1,181 / 591 / 1,181

ft-lb

18 / 9

22 / 11

21


MANUFACTURING SYSTEM FOR GEARS WITH MOD Complete production lines can be installed with ease using the EMAG modular principle - due to the combination of identical machine structures and the TrackMotion automation system which is designed perfectly to fit this concept. The strengths of this standard approach are demonstrated by the example of this production line for gears, which has been created using nothing but components from our range of modular machines. The identical transfer height and i­ntegrated automation of this system allows multiple machines to be linked together using the TrackMotion automation system - creating a particularly lean manufacturing system.

Turning of the first side

OP 10: Machining the first side of the raw part (external turning and internal t­ urning of the surfaces).

22

Turning of the second side

OP 20: Machining the second side of the raw part (external turning and internal turning).

Gear hobbing

Deburring / Chamfering

OP 30: Dry gear hobbing of the gears.


DULAR MACHINES VERTICAL PICK-UP GEAR HOBBING MACHINE I Manufacturing System for Gears

TRACKMOTION, THE PERFECT AUTOMATION SYSTEM The TrackMotion a­ utomation system is the perfect a­ ddition to a lean p ­ roduction line. In this case, two TransLift units are used, one for loading, OP 10 and OP 20, and one for OP 30, OP 40 and unloading the ­workpiece.

Machines shown with optional decorative sheet metal kit

The use of stacker pallets allows for hours of autonomous production. The flexibility provided by the TrackMotion, and the ­universal approach which it allows, are essential for a lean production line because no other automation components are required.

OP 40: Deburring the workpiece using roller burring.

23


Automatic raw part supply

Turning of the first side (OP 10)

Turning of the second side (OP 20)

MANUFACTURING SYSTEM FOR GEAR MACHINING From solid bulk material in the form of sawn parts, to finished gear in less than 40 seconds – an excellent example of the performance of EMAG modular machines.

Complete Process Chains from EMAG With the VL 3 DUO vertical twin-spindle pick-up turning ­machine and the VL 4 H vertical gear hobbing machine, EMAG offers the perfect manufacturing system for the complete machining of gears. The machines are supplemented by the TrackMotion automation system which ensures smooth part transportation between the machines – including the turning of the workpieces and placing them on stackable pallets.

24

VL 3 DUO: HIGHLY PRODUCTIVE ­MANUFACTURING IN JUST 264 ft² ++ Fast automation: machining OP 10 + OP 20 incl. handling and turning in only 23 sec.

++ Machining times beginning at 15 sec., no machine downtime ++ Up to 400 parts can be held in parts storage area

TECHNICAL DATA Workpiece diameter / length Chip-to-chip time Spindle capacity (40% duty cycle) Torque (40% duty cycle)

6 / 4 in 5 – 6 sec. 24 HP 106 ft-lb


37 SECOND CYCLE TIME

Parts storage area for up to 400 workpieces including TrackMotion

VL 4 H: FASTEST PICK-UP GEAR HOBBING ­MACHINE WORLDWIDE ++ High-speed pick-up gear hobbing machine for the milling of chucked parts with a tailstock

++ Excellent chip flow – ideal for high-performance dry gear hobbing ++ Measuring probe for post-process measurement with optional ­process stabilization

MANUFACTURING SOLUTIONS FOR SPROCKETS I Manufacturing System for the Machining of Sprockets

Gear hobbing (OP 30)

VL 2 RC: EXCELLENT CHAMFERING RESULTS IN LINE CYCLE TIME ++ No moving around of parts, chamfering performed in the line ++ Separate and downstream chamfering resulting in no machining time delays for gear hobbing

++ Maximum reduction of secondary burrs and material bulging

++ Tailstock ensures optimum stability and maximum tool service life

TECHNICAL DATA Module Workpiece diameter / length Max. angle of inclination Axial cutting distance, max.

4 8 / 14 in +/- 35° 6 in

TECHNICAL DATA Max. module Max. workpiece diameter / length Max. feed force Ball screw spindle drive Main spindle max. speed

4 8 / 8 in 1,124 lbs 1 in 6,000 rpm

25


Turning

Milling

Grinding

Gear Hobbing

AT HOME ALL OVER THE WORLD. EMAG Salach GmbH Salach

Leipzig

Austria

Austrasse 24

Pittlerstrasse 26

Glaneckerweg 1

73084 Salach

04159 Leipzig

5400 Hallein

Germany

Germany

Austria

Phone: +49 7162 17-0

Phone: +49 341 4666-0

Phone: +43 6245 76023-0

Fax:

Fax:

Fax:

+49 7162 17-4027

+49 341 4666-2114

+43 6245 76023-20

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81677 München

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Germany

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Fax:

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+45 75 816276

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Market Companies EUROPE

AMERICA

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Chestnut House

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Farmington Hills, MI 48335

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Phone: +39 02 905942-1

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Phone: +1 248 477-7440

Fax:

Wolverhampton WV7 3AU

Fax:

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E-mail: info@usa.emag.com

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Phone: +44 1902 37609-0 EMAG MILANO S.r.l.

Fax:

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ul. Akademika Chelomeya 3/2

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Phone: +33 248 7711-00

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Fax:

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Phone: +52 442 291 1552

+33 248 7111-29

E-Mail: info.france@emag.com

Phone: +7 495 287 0960 Fax:

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E-mail: info@mexico.emag.com

+7 495 287 0962

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Phone: +55 11 38370145

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Sanayi Cad. No.: 44

73130 Köping

103 00 Praha 10 – Kolovraty

Nish İstanbul Sitesi D Blok

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D: 155 Yenibosna – Istanbul

Phone: +46 221 40305

Phone: +420 731 476070

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E-mail: info@sweden.emag.com

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Phone: +90 532 694 54 44

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ul. Krzycka 71A / 6

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53-020 Wrocław

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Phone: +36 30 9362-416

Phone: +48 728 389 989

E-mail: lbujaki@emag.com

E-mail: info@poland.emag.com

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EMAG INDIA Pvt. Ltd.

Building A3 & B7 Cangneng

Technology Centre

Europe & America Technology Park

No. 17/G/46-3, Industrial Suburb,

No. 8 Loujiang Rd. (N.)

2nd Stage, Yeshwantpur,

215400 Taicang

Bengaluru – 560 022

Jiangsu, China

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Phone: +86 512 5357-4098

Phone: +91 80 50050163

Fax:

E-mail: info@india.emag.com

+86 512 5357-5399

E-mail: info@emag-china.com EMAG KOREA Ltd. EMAG (Chongqing) Machinery Co., Ltd.

Rm204, Biz center, SKn Technopark,

No. 10th Lailong Road

124 Sagimakgol-ro, Sangdaewon-dong,

Yongchuan District

Jungwon-gu, Seongnam City,

402160 Chongqing

Gyeonggi-do, 462-721

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Phone: +86 23 49783399

Phone: +82 31 776-4415

Fax:

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+81 76 274-8530

E-mail: info@takamaz.emag.com

+82 31 776-4419

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Induction Hardening


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