Invitation to the Technology Forum 2016 (EN)

For information and to register, go to: technologieforum.emag.com

APRIL 21-22, 2016 I EMAG SALACH

INVITATION TO THE EMAG TECHNOLOGY FORUM 2016

Experience machining live!

The technology companies within the EMAG Group present innovative manufacturing solutions through live demonstrations and technical presentations.

www.emag.com

EMAG TECHNOLOGY FORUM 2016

THINK VERTICAL “THERE IS NOTHING MORE CONSTANT THAN CHANGE.” Charles Darwin

Jürgen Müller

Managing Director, EMAG Salach GmbH 2016 is the Year of the Fire Monkey in China. This lively animal represents above all new momentum and change.

The Year of the Fire Monkey is a good time for inventions. A good time to look again at familiar things from a new perspective and rediscover them – in other words to do things differently.

On the basis of this, here at EMAG we also want to do things differently and give fresh impetus to our events.

We want to start these changes with our Technology Forum to which I hereby cordially invite you.

Close to the technology, close to the machines and close to the customer – this is the motto of the Technology Forum 2016 which features a whole new range of presentations at a new location. I hereby invite you to join us in taking a look at technological innovations and the exciting opportunities which the EMAG Group can deliver to its customers.

EMAG’s approach to 2016 will be characterized by numerous new products inspired by ingenuity. Come and see for yourself at this year’s EMAG Technology Forum which will take place on Thursday, April 21, and Friday, April 22.

I look forward to welcoming you here in Salach.

Jürgen Müller

EMAG TECHNOLOGY FORUM 2016

THE HIGHLIGHTS PRESENTATION: FULLY NETWORKED – FULLY UNDER CONTROL? How intelligent data management and networked series production are revolutionizing quality management.

Digitization was the mega trend of the new millennium. Social life has now become unthinkable without digital media, and completely new areas of business have been developed relating to data analysis. It is therefore a quite legitimate question to ask how digitization and data analysis will change industrial manufacturing.

One answer to this question, from the point of view of EMAG at least, will be delivered by Dr. Achim Feinauer, COO of EMAG GmbH & Co. KG. In the field of series production in particular, networked lines and the resultant data deliver possibilities for quality management which were previously unheard of. This presentation will look at how these can be used sensibly and what conclusions can be drawn for planning future manufacturing projects.

Thursday and Friday at 9.45 am in the auditorium.

PRESENTATION: SOMETIMES THERE HAVE TO BE TWO Presentation of the new VL 3 DUO and answers to the question: “When does it make sense to use twin-spindle machines?”

The VL 3 DUO is the new highlight for the vertical machining of chucked parts. In the development of the VL 3 DUO, special attention was paid to the requirements of large batch production. The VL 3 DUO is a particularly interesting product for manufacturing gearbox components in huge quantities and with maximum precision.

Mathias Klein, Gearbox Department Manager at EMAG Maschinenfabrik GmbH, will explain why the VL 3 DUO makes particular sense for this application and what technical highlights EMAG engineers have given it.

Thursday and Friday at 11 am and 11.50 am in Presentation Area 1.

SHOP FLOOR TOURS “Experience machining live” On both days of the event, there will of course be guided tours through the production halls at EMAG as at previous events. Here, you will be able to see the new modular machines and experience the entire range of EMAG technologies. From laser welding and induction hardening to electro-chemical machining and classic machining processes such as turning, milling, grinding and gear cutting – EMAG always has the perfect solution.

Thursday and Friday at 2.40 pm.

SHOP FLOOR TOURS Experience machining live!

EMAG TECHNOLOGY FORUM 2016

TECHNICAL PRESENTATIONS – THURSDAY, APRIL 21, Time

Presentation

Location

9:00

Registration

Reception

9:30

Welcome Jürgen Müller, EMAG Salach GmbH

9:45

Fully networked – fully under control?

How intelligent data management and networked series production are revolutionizing quality management.

Auditorium Auditorium

Dr. Achim Feinauer, EMAG GmbH & Co. KG 10:15

Highly efficient manufacturing

How manufacturing systems for series production can be designed to be simple, flexible yet powerful, with examples from EMAG.

Auditorium

Dr. Guido Hegener, EMAG Maschinenfabrik GmbH 10:45

Break and handing out of headsets

11:00

Sometimes there have to be two

Presentation of the new VL 3 DUO and answers to the question: “When does it make sense to use twin-spindle machines?”

Mathias Klein, EMAG Maschinenfabrik GmbH Faster grinding

How conventional limits can be broken by synchronous grinding and the opportunities of combination machining.

Roland Schmitz, EMAG Maschinenfabrik GmbH 11:20

Up and running! – The V-series

Self-loading pick-up turning machines of the VL-series for an automated manufacturing process.

Achim Trommsdorf, EMAG Salach GmbH Shaft machining

Two turrets + four axis = highly productive shaft manufacturing – How the VT-series from EMAG has successfully transferred the pickup principle to shaft production.

Presentation Area

1

Presentation Area

2

Presentation Area

1

Presentation Area

2

Ronald Matzig, EMAG Salach GmbH 11:40

Break

11:50

Sometimes there have to be two

Presentation of the new VL 3 DUO and answers to the question: “When does it make sense to use twin-spindle machines?”

Mathias Klein, EMAG Maschinenfabrik GmbH Faster grinding

How conventional limits can be broken by synchronous grinding and the opportunities of combination machining.

Roland Schmitz, EMAG Maschinenfabrik GmbH

Presentation Area

1

Presentation Area

2

REGISTRATION For further information and to register, go to: technologieforum.emag.com We look forward to seeing you there!

AND FRIDAY, APRIL 22, 2016 Time

Presentation

Location

12:10

Up and running! – The VL-series

Presentation Area

Self-loading pick-up turning machines of the VL-series for an automated manufacturing process.

Achim Trommsdorf, EMAG Salach GmbH Shaft machining

Two turrets + four axis = highly productive shaft manufacturing – How the VT-series from EMAG has successfully transferred the pick-up principle to shaft production.

Ronald Matzig, EMAG Salach GmbH 12:30

Lunch break

13:30

Laser welding

The slenderizing expert – How the perfect symbiosis of turning, joining and laser welding makes weight-optimized components possible.

Dr. Andreas Mootz, EMAG Automation GmbH Extreme machining

Machining large chucked parts with complex geometries perfectly with the milling / turning technology of the VMC MT-series.

13:50

Presentation Area

2

Presentation Area

1

Presentation Area

Tino Freigang, EMAG Leipzig GmbH

2

Gear hobbing of non-circular gears

Presentation Area

The horizontal hobbing machines from EMAG KOEPFER can be used to carry out even extremely demanding jobs, such as the cutting of noncircular gears.

Manuel Hofmeier, EMAG KOEPFER GmbH Compact and flexible

Excellent performance in a very small space and a large selection of equipment versions make the MIND-M an all-purpose solution for a wide range of hardening tasks.

Andreas Endmann, EMAG eldec Induction GmbH 14:10

Break

14:20

There’s no such thing as too hard

How PECM technology has developed into an efficient alternative to machining and eroding hard materials.

Richard Keller, EMAG ECM GmbH Swung down to a minimum – reduced idle times thanks to pendulum technology

Large series production of strategic components such as cams and cam parts using the example of the VLC 200 CG

Jürgen Müller, EMAG Salach GmbH 14:40

1

Guided tours of the production halls

1

Presentation Area

2

Presentation Area

1

Presentation Area

2

VL 3 DUO

WORLD PREMIERE – THE VL 3 DUO FROM EMAG 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 diameter of up to 150 mm.

The VL 3 DUO features the new technological developments of the last few years (from pick-up automation and the TrackMotion automation system to the modular basic design of the machine) to create a highly productive manufacturing system which delivers maximum productivity with a minimum footprint.

WORLD PREMIER

PERFORMING LIVE

HIGHLIGHTS + Two machining areas for OP 10 and OP 20.

Each machining area features a high-performance pick-up spindle and a tool turret with 12 tool positions.

+ The TrackMotion automation system not only

ensures fast parts transport between the parts storage facility and machining areas but also turns the components between OP 10 and OP 20.

+ Its compact design ensures maximum produc-

VL 3 DUO VL 2 10 100 150 200 300 400

Workpiece diameter

Workpiece length

250 200

VL 4

110

VL 6

150

VL 8

300

TECHNICAL DATA Workpiece diameter, max.

mm

150

Chuck diameter

mm

210

Workpiece length, max.

mm

110

Travel distances X (machining stroke) / Y (optional) / Z

mm

505 / ± 30 / 250

» Power rating 40 % / 100 %

kW

18,1 / 13,9

» Torque 40 % / 100 %

Nm

77 / 59

1/min

5.200

Main spindle (2x)

» Number of revolutions, max.

inch inch inch inch

hp

ft-lb rpm

» Spindle flange to DIN 55026 » Spindle bearing dia., front Turret (2x) » Turret tool positions Rapid-traverse rate X / Y / Z

6 8

4.5

19.5 / ± 1 / 10

24 / 19

57 / 44

5,200

Size 6 mm

100

Qty m/min

12 60 / 30 / 30

inch

4

ipm 2,363 / 1,181 / 1,181

Machines shown with optional decorative sheet kit

tivity with a minimum footprint. Nevertheless, both machining areas are easily accessible which minimizes set-up times.

THE COMPLETE VL-SERIES LIVE!

PICK-UP TURNING MACHINES FOR CHUCKED PARTS High productivity with a minimum footprint – that is what the vertical, fully automated turning machines in the VL-series guarantee.

This is where it all comes together – these CNC turning machines require very little space, are simple to operate and load themselves with their automation system. The user can set them up in a single step – robots or portals are completely superfluous. High-quality components and the typical EMAG vertical machining also ensure a particularly high machining quality.

PERFORMING LIVE

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

thanks to compact machine design

+ MAXIMUM PERFORMANCE

TECHNICAL DATA

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

700 / ± 50 / 375

740 / ± 30 / 400

880 / ± 30 / 480

995 / ± 30 / 580

» Power rating 40 % / 100 %

kW

18,1 / 13,9

25 / 18

39 / 28

44 / 34,5

» Torque 40 % / 100 %

Nm

77 / 59

280 / 202

460 / 340

775 / 600

1/min

6.000

4.500

3.100

2.850

Main spindle

» Number of revolutions, max.

Turret » Turret tool positions » Revolutions of driven tools » Torque of driven tools at 30 % / 100 % ED Rapid-traverse rate X / Y / Z

inch inch inch inch

hp

ft-lb rpm

6.5

6

27.5 / ± 2 / 15

24 / 19

57 / 44 6,000

10 8

29 / ± 1 / 15.5

36 / 24

223 / 149

4,500

15.5

10

34.5 / ± 1 / 19

52 / 38

339 / 251 3,100

15.5

19.5 12

39 / ± 1 / 23

59 / 46

572 / 443

2,850

Qty 1/min

12 6.000

12 6.000

12 6.000

12 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

rpm

ft-lb ipm

6,000

20 / 11

2,363 / 1,181 / 1,181

6,000

20 / 11

2,363 / 591 / 1,181

6,000

20 / 11

2,363 / 591 / 1,181

6,000

35 / 22

2,363 / 591 / 1,181

Machines shown with optional decorative sheet kit

thanks to short transport distances

VSC 250 DUO

MULTI-SPINDLE MACHINE FOR MEDIUM TO LARGE-SCALE SERIES PRODUCTION The evolution of the classic – the new VSC 250 DUO. The DUO machines of the VSC-series are among the favorites of many production planners. Some of the reasons that these machines are used in so many production halls include the compact design, maximum productivity thanks to the two machining areas and short distances for loading and unloading.

EMAG proves that good things can be made even better with the completely redeveloped VSC 250 DUO which will be unveiled at the Technology Forum. Even more precise, even more productive and thanks to its even larger Z-stroke, now suitable for an even wider range of parts.

THE BENEFITS + Modular design with many options + Optional Y-axis + Long tool service lives due to excellent damping

+ Maximum rigidity of the body for excellent machining results

+ Z-stroke up to 300 mm + Top thermal stability

TECHNICAL DATA Chuck diameter, max.

mm

315

Swing diameter

mm

330

Workpiece diameter, max.

mm

250

Travel distance X

mm

900

Travel distance Z

mm

300

inch inch inch inch inch

12.5 13

10

35.5

12

VMC 300 MT

VERTICAL MACHINING CENTER FOR DEMANDING PART GEOMETRIES With its VMC MT-series, EMAG provides its customers with an opportunity to manufacture complex, heavy chucked parts highly efficiently, vertically and flexibly.

Machines shown with optional decorative sheet kit

The spindle at the bottom in various designs allows even heavy-duty machining processes to take place and is perfectly supplemented by the milling spindle and the extensive tool magazine with up to 80 tools.

THE BENEFITS + Developed for the present and future-ready for Industry 4.0 + Perfect for small and medium-sized series as well as part

families and prototype production with maximum flexibility up to 24/7

+ Suitable for universal use – highly flexible manufacturing of a wide range of workpieces and materials

+ Machine concept which can be optimally adapted to the

machining process required – large selection of technology modules

+ The number of tools can be extended and downtimes reduced by using mini tool carriers

TECHNICAL DATA Chuck diameter, max.

mm

315

Swing diameter over base

mm

500

Diameter, max.

mm

300

Travel distances X / Z

mm

340 / 480

Spindle height (without clamping devices)

mm

970

inch inch

inch inch inch

12.5 19.5 12

13.5 / 19

38

KOEPFER K 160

HORIZONTAL GEAR HOBBING MACHINE FOR VARIAB For many years, EMAG KOEPFER has been synonymous with very high quality in the development and manufacture of gear cutting machines.

This tradition is also continued with the horizontal gear hobbing machine K 160, that can be conďŹ gured for a wide variety of gear cutting tasks thanks to its axes and drives which can be optimally controlled.

The K 160 is the perfect solution for high-speed gear cutting up to module 2.5 for both dry and wet machining thanks to its wide range of automation and technology modules.

PERFORMING LIVE

BLE APPLICATIONS

THE BENEFITS + High vibration damping and therefore long tool service lives and high surface quality

+ MINERALIT速 polymer concrete is thermally stable which ensures constant production results

TECHNICAL DATA Module, max.

2,5

Workpiece diameter

mm

90 / 140

Cutting distance

mm

200 / 480

Workpiece length

mm

300 / 1.000

Cutter width

mm

250

Shift travel

mm

160

Main spindle speed

1/min

4.000

Hob speed

1/min

5.000

inch inch inch inch inch rpm rpm

3.5 / 5.5 8 / 19

12 / 39.5

10

6.5

4,000 5,000

VLC 100 GT

VERTICAL PRECISION FINISHING MACHINE Pick-up automation, variably configurable working area and a selection of high precision machining technologies are the main features of the VLC 100 GT vertical precision finishing machine.

Whether it is gear wheels, planetary gears, sprocket wheels or even non-circular components such as cams, the VLC 100 GT can finish a wide range of components due to its optimally configurable machining area. Thanks to its integrated automation system and vertical design, it guarantees maximum productivity with a minimum footprint.

TECHNICAL DATA Chuck diameter, max.

mm

160

Swing diameter, max.

mm

210

Machining diameter, max.

mm

100

Travel distance X

mm

900

Travel distance Z

mm

375

inch inch inch inch inch

6.5

8.5 4

35.5 15

VTC 100 GT

HIGHLY PRODUCTIVE SHAFT MANUFACTURING The VTC 100 GT offers quick processes for hard turning and grinding: the tool turret completes all turning operations, while the grinding then starts at the second station.

While strong workpieces with a defined blade can be finish-machined by hard turning or using scroll-free turning technology, a final grinding process is the method of choice for thinner and more fragile parts.

Machines shown with optional decorative sheet kit

This high flexibility in equipment and technology enables it to machine a wide range of parts. The machine’s possible workpieces include gearbox shafts, rotor shafts, pump shafts and engine shafts as well as propeller and balancing shafts.

TECHNICAL DATA Chuck diameter, max.

mm

160

Workpiece diameter, max.

mm

100

Workpiece length, max.

mm

400

Travel distance X

mm

340

Travel distance Z

mm

660

inch inch inch inch inch

6.5 4

15.5

13.5 26

PECM / INDUCTION HARDENING / PRODUCTION LASER WELDING

HIGH-TECH TECHNOLOGIES LIVE PECM TECHNOLOGY Precise electrochemical machining (PECM) is the ideal process for the noncontact, almost wear-free machining of workpieces made of high strength materials such as nickel-based alloys. At the EMAG Technology Forum, we will be exhibiting the PECM machine PTS 2500, a system for the effective machining of extremely demanding 2-D and 3-D contours.

INDUCTION HARDENING The MIND-M 250 hardening machine for induction hardening offers a high degree of precision and reliability at comparably low investment costs. Simple heat treatment tasks, such as hardening or induction hardening, with a maximum power requirement of 30 kW in high frequency (HF) or 100 kW in medium frequency (MF) applications can be processed with the MIND-M 250.

PRODUCTION LASER WELDING Modern vehicles are now inconceivable without laser beam welding.

Laser beam welding is a prerequisite for compact, weight-optimized components and therefore for energy-efficient vehicles. You benefit from high welding speeds and minimum warping on the welded components.

PTS 2500 – PECM SYSTEM + Machine base made of MINERALIT® polymer concrete

+ Clamping surface: 800 x 550 x 515 mm (W x D x H)

+ Machining area size: 1,070 x 700 mm (W x D)

+ Space requirement: 2,100 x 3,200 x 2,900 mm (W x D x H)

+ Oscillator with play-free precision drive

MIND M – COMPACT HEATING SYSTEM + Workpiece diameter, max.: 350 mm + Workpiece length, max. (MIND-M 250 / MIND-M 1000): 250 / 1,000 mm

+ Workpiece weight, max.: 10 kg + eldec medium frequency generator model MFG 100

+ Twin spindle and dual tailstock

ELC 160 – LASER WELDING MACHINE + Welding diameter, max.: 160 mm + Workpiece diameter, max.: 200 mm + Three component versions can be produced using this device

+ Complete machining of powertrain

components (for example: joining / laser welding, radial or axial / inductive preheating)

Plochingen A8

B 10

B 313

Göppingen Salach

Süssen

B 466

Heidenheim

Geislingen

A7

A 81 B 10

A8

HOW TO FIND US

A8

ULM

TECHNOLOGY FORUM 2016 0

10

20

40

30

50km

B 311

For information and to register, go to: A7 technologieforum.emag.com B 30

April 21-22, 2016 EMAG Salach

EMAG Salach GmbH Austrasse 24 73084 Salach Germany

Plochingen

Richtung / Direction Esslingen/ Stuttgart

Eislingen

B 10

Salach

B 313

A8

Phone: +49 7162 17-0 Fax: +49 7162 17-820 E-mail: event@emag.com

Göppingen

Süssen

BAB-Ausfahrt/ Exit 55 Wendlingen

B 466

Geislingen

P rasse

R D ichtu Eislirectio ng/ inge n n

Aust

Teck st

B 10 Richtung / Direction Stuttgart

A 81

Richtung/ Direction München

BAB-Ausfahrt/ Exit 62 Ulm-West

Richtung / Direction Ulm

B 10

B 10

A8

rasse

ULM

EMAG Salach GmbH

Austrasse 24 · 73084 Salach Telefon: +49(0)7162/17 - 0 · Telefax: +49(0)7162/17 - 820 E-Mail: info@emag.com · www.emag.com

STUTTGART A8

Esslingen A8

Plochingen B 313

B 10

Göppingen Salach

Süssen

B 466

Heidenheim

Geislingen

A7

A 81 A8

B 10

A8

ULM 0

10

20

30

40

50km A7 B 311

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B 30

www.emag.com