Production Systems for Large Workpieces en

Production systems for large workpieces

Precision + Power = VLC Workpieces are becoming more complex and precise, batch sizes are becoming smaller, and throughput times are becoming shorter. In order to keep up with these changes, use the powerful, multi-functional machines of the VLC Series. Thanks to technology integration, with the VLC series, production takes place with only a single clamping operation.

Integration of the processes on a single machine makes sense for small batch sizes because a decrease in re-clamping operations leads to increased precision and a reduction in the possibility of errors. EMAG has created a stable platform which unites turning, drilling, milling, grinding, and gear cutting up to a diameter of 1,200 mm on a single machine.

Complete machining in two clamping operations Technologies

Turning, drilling, and thread milling

Clamping device

EMAG 6-jaw chuck with automatic quick jaw change

Material

Gray cast iron GGG 42

Machine data: Machine

VLC 500

Max. chuck diameter

500 mm | 19.7 inch

Swing diameter

820 mm | 32.3 inch

Power rating of main drive unit

110 kW | 148 hp

Max. torque

1,300 Nm | 959 ft-lb

Rapid-traverse rate X / Z

45 / 20 m/min | 1,772 / 787 ipm

Feed force X / Z

25 / 10 kN | 5,620 / 2,248 lbf

Tool carrier

2 x tool turret, each with up to 12 powered tools

VLC – Multi-functional production centers Flexible machining solutions are the key to cost reduction for small to moderate batch sizes. The focus, for the VLC, is on capacity utilization of production systems. The machining operations must be distributed uniformly over the machines. Precise time coordination of the individual operations in the sequence plays a crucial role in serial processes.

One renowned manufacturer of construction machines attached particular importance to this aspect in replacement procurement of a drilling center for machining ring gears. They opted for a VLC 500 vertical, multifunctional production center from EMAG. The machine was integrated in an existing manufacturing system and covers a broad range of workpiece variants.

Machining in two clamping operations Technologies

Turning and drilling

Clamping device

EMAG special-purpose clamping chuck for all workpiece variants

Material

20CrMo4

Workpiece variants

30 pcs

Machine data: Machine

VLC 500

Max. chuck diameter

500 mm | 19.7 inch

Swing diameter

820 mm | 32.3 inch

Power rating of main drive unit

110 kW | 148 hp

Max. torque

1,300 Nm | 959 ft-lb

Rapid-traverse rate X / Z

45 / 20 m/min | 1,772 / 787 ipm

Feed force X / Z

25 / 10 kN | 5,620 / 2,248 lbf

Tool carrier

2 x tool turret each with up to 12 tools, CDI 80 interface

VLC – Tailwind for machining The boom in the wind power industry is relentless. Investments are being made in renewable energies worldwide, and wind power plants are one of the main focuses. Consequently, the demand for drives used in constructing wind power systems are also increasing.

Components for azimuth drives for swiveling the gondola and pitch drives for angle adjustment of the individual rotors are machined on a VLC 500 MT. The machine manufactures drive housings, planetary carriers, and annulus gears made of cast iron or steel. In the process, turning, milling, and drilling technologies are used. Annual production is around 6,000 workpieces manufactured in batch sizes of 120 parts per week.

Machining of components for the drive unit Technologies

Turning, milling, and drilling

Clamping device

EMAG special-purpose clamping chuck for all workpiece variants

Materials

Cast iron, steel

Workpiece variants

6 pcs

Machine data: Machine

VLC 500 MT

Max. chuck diameter

500 mm | 19.7 inch

Swing diameter

820 mm | 32.3 inch

Power rating of main drive unit

110 kW | 148 hp

Max. torque

1,300 Nm | 959 ft-lb

Rapid-traverse rate X / Z

45 / 20 m/min | 1,772 / 787 ipm

Feed force X / Z

25 / 10 kN | 5,620 / 2,248 lbf

Tool carrier

1 x tool turret each with up to 12 powered tools, 1 x milling spindle with tool changer for max. 40 tools

Custom-made solutions – Complete machining by technology integration

The modular-structured machining area of the VLC 800 can be fitted with a VDI 60 turning turret for heavy-duty machining and a second drilling turret with powered tools. It is also possible to integrate milling spindles for machining spur gears or multi-functional machining with a disk-type turret and a motor spindle with Y/B-axis. The integrated A-axis also allows helical gearing to be implemented and the B-axis allows for angle-plunge grinding. By contrast, if the focus is on turning, the machine can be equipped with two turrets.

Machining of brake disks Workpieces

Brake disks

Technologies

Turning, drilling, milling, reaming, and thread machining

Material

GGV 30

Machine data: Machine

VLC 800

Max. chuck diameter

800 mm | 31.5 inch

Swing diameter

820 mm | 32.3 inch

Power rating of main drive unit

46 kW | 62 hp

Max. torque

3,100 Nm | 2,286 ft-lb

Rapid-traverse rate X / Z

45 / 20 m/min | 1,772 / 787 ipm

Feed force X / Z

25 / 10 kN | 5,620 / 2,248 lbf

Tool carrier

1 turret with 12 stations, ingot turning tool holder

All-in-one – including automation The basis of the VLC Series is a sturdy main body made of high-grade MINERALITŽ polymer concrete. This type of construction guarantees maximum precision, excellent surface quality, and longer tool service life when machining chuck parts. The working spindle with the workpiece traverses on the main axes X and Z, optionally on the Y-axis. The tool carriers may be used in pendulum mode in series or in parallel.

This is made possible by an additional X and Z-axis. Measuring is also an integral part of the VLC construction principle.

En route from the machining position to the deposit position, the workpiece is brought to the stationary probe or gauge arbor outside the machining area.

Therefore, measuring results are not influenced by chips or dirt. Measuring is carried out in the machining position.

Machining of rims Workpiece

Rims

Technologies

Turning, drilling and deburring

Clamping device

EMAG special-purpose clamping chuck 6+6 with opposed chucking points

Materials

St52 / St37

Machine data: Machine

VLC 800

Max. chuck diameter

800 mm | 31.5 inch

Swing diameter

820 mm | 32.3 inch

Power rating of main drive unit

46 kW | 62 hp

Max. torque

3,100 Nm | 2,286 ft-lb

Rapid-traverse rate X / Z

45 / 20 m/min | 1,772 / 787 ipm

Feed force X / Z

25 / 10 kN | 5,620 / 2,248 lbf

Tool carrier

Ingot tool holder with hydraulic retraction holder, fixture for quadruple or quintuple multi-spindle head in console

The fully automated machining of large workpieces The VLC 800 MT multi-functional production center allows for the complete machining of workpieces with a diameter of up to 800 mm in one clamping operation. This replaces the carousel turning machines used in the past for such large workpieces. The sturdy main spindle traverses horizontally in X direction and vertically in Z direction. In addition, the milling spindle executes the transverse movement in Y direction. The machine base is made of MINERALITÂŽ polymer concrete and ensures excellent vibration damping. This minimizes tool wear even with discontinuous cutting and ensures optimum surface quality. The spindle motor, the main spindle with quill, the tool turret, and the electrical cabinet are liquidcooled. A dual-circuit cooling unit readjusts the machine temperature to the ambient temperature within close tolerances. Consequently, the VLC turning centers produce even large components with accuracies in the range of a hundredth of a millimeter.

Machine data Machine

VLC 800 MT

Max. chuck diameter

800 mm | 31.5 inch

Swing diameter

820 mm | 32.3 inch

Power rating of main drive unit

46 kW | 62 hp

Max. torque

3,100 Nm | 2,286 ft-lb

Rapid-traverse rate X / Z

45 / 20 m/min | 1,772 / 787 ipm

Feed force X / Z

25 / 10 kN | 5,620 / 2,248 lbf

Tool carrier

1 x tool turret each with up to 12 tools, 1 x milling spindle with tool changer for max.

96 tools

Heavy-duty machining with maximum precision A workpiece including a clamping device totaling 3 tons on the spindle nose: this makes it easy to imagine the size of the VLC 1200. It is used, for complete machining of planetary carriers, train wheels, or for grinding ceramic brake disks. With the VLC platform, EMAG covers the large 500, 800, and 1,200 mm chuck diameters. The concept ranges from the twin-axis machine to the five-axis pick-up machine.

Machining of workpieces up to Ø 1,000 mm and 1.5 ton in weight Technologies

Turning, drilling, and thread machining

Clamping device

EMAG 3-jaw special-purpose clamping chuck

Machine data: Machine

VLC 1200

Max. chuck diameter

1,250 mm | 49.2 inch

Swing diameter

1,500 mm | 59.1 inch

Power rating of main drive unit

88 kW | 118 hp

Max. torque

11,000 Nm – max. 13,000 Nm | 8,113 ft-lb – max. 9,588 ft-lb

Rapid-traverse rate X / Z

25 / 25 m/min | 984 / 984 ipm

Feed force X / Z

25 / 15 kN | 5,620 / 3,372 lbf

Tool carrier

1 x turning tool holder, 1 x milling spindle with tool changer

Tool changer

Chain-type magazine with 36 tool positions

Tool socket

HSK 100 / planar support 160

Advantages of the VLC Series…

Self-loading system with positioning of the 99

… and your benefits ++ Increased flexibility and cost savings since

Complete machining by a combination of 99

++ Increased flexibility and shortening of the

workpieces in the main spindle

various technologies in a single machine

external loading units are not required

process chain by saving on other machines

++ Increase in precision because of a reduction in number of clamping operations and machines

Compact, enclosed design thanks to 99

++ Longer service lives, higher accuracies,

Overhead vertical main spindle, chips fall 99

++ No risk of surface damage and tool

All main units thermally cooled 99

++ Long-term accuracy and short start-up

Turret with 12 tool stations fully integrated 99

++ High flexibility in machining, longer service

Wide-opening machining area doors with 99

++ Easy and quick machine set-up and good

Modular machine concept with components 99

++ Implementation of your specific

channeled machine base made out of MINERALIT® polymer concrete, which has 6–8 times better vibration damping than gray cast iron down unhindered

in the machine base large window areas

that have been tested thousands of times

and higher surface qualities, especially in the case of brittle and hard materials

influencing, specifically when drilling times

lives, and better surface quality

visibility of the machining process

requirements and, at the same time, high technical availability of the overall system

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