BU Turning (EN) by EMAG Group

BUSINESS UNIT TURNING

Turning machines for chucked and shaft parts

Turning machines for chucked parts

VL Modular Solutions p. 6

VLC Modular Customized Solutions p. 12

VSC Customized Solutions p. 14

Turning machines for shaft parts

VT Modular Solutions p. 24

VTC Modular Customized Solutions p. 26

TURNING MACHINES CHUCKED PARTS FOR

VL MODULAR SOLUTIONS

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

MAXIMUM PRECISION – DIRECT POSITION MEASURING SYSTEMS

M/MIN

THE PATENTED EMAG TURRET

+ Glass scales – Fully encapsulated linear glass scales in all linear axes.

+ Standard – Glass scales come standard on all EMAG machines! Measuring

+ Fast, with zero play and wear – the EMAG turret is equipped with a direct drive (torque motor) for swiveling.

+ Precise – Thermal stability is ensured thanks to an ambient temperature controlled cooling system.

+ Flexible – The turret has space for twelve tools (featuring either a VDI or BMT interface). Driven tools can be used in all tool stations. The optionally available Y-axis ensures maximum ﬂ exibility.

BENEFITS OF THE VL SERIES

+ High strength

Large working spindle bearing diameter + MINERALIT® polymer

concrete machine body

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

VL MODULAR SOLUTIONS

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 up to 100/200 mm. They feature integrated automation and a parts storage area, which enables them to operate completely autonomously, relieving the strain on production personnel. Efficient mass production of varying batch sizes is possible and, thanks to ﬂexible clamping systems, they can also easily machine whole part families.

Cover

Machines: VL 2

Sawn part diameter: 100 mm

Material: X5CrNi1810 2 OPs

Main hub

Machines: VL 4 Forged part diameter: 120 mm Material: 16MnCr5 2 OPs

Intermediate gear

Machines: VL 2

Sawn part diameter: 60 mm Material: C45 2 OPs

Sprocket

Machines: VL 2

Pre-forged part diameter: 50 mm

Material: 16MnCr5 2 OPs

Piston

Machines: VL 4

Sawn part diameter: 100 mm Material: 46S20 2 OPs

VL 6 and VL 8 for large workpieces

Machine larger workpieces, or achieve maximum ﬂexibility in production with a VL 6 or VL 8 pickup turning machines. Integrated conveyor belt makes loading the machines with heavy parts a breeze. Place parts on the conveyor belt by crane and the machine takes care of everything else.

Drive gear

Spur gear

Main spindle

VL MULTI-SPINDLE MACHINES – VL 3 DUO

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 150 mm (6 inches) in diameter.

The VL 3 DUO integrates all of the most recent EMAG technological developments (including self-loading spindle, the TrackMotion automation system and the modular design of the machine) to create a highly productive manufacturing system with a minimum footprint.

automation system

Spindle 1

Parts storage area

Access to e-container and hydraulics

HIGH-PERFORMANCE TURNING WITH THE VL 3 DUO

Spindle 2 OP 20 NC shuttle Central machining area extraction unit

The VL 3 DUO scores highly for heavy-duty machining due to its rigid machine design. High feed forces with a large cutting depth reduce the machining time.

Standard spindle:

ap = 4.75 mm

0.2 in

f = 0.4 mm/rev 0.02 in/rev

v c = 250 m/min 1,000 in/min

High torque spindle:

ap = 8.5 mm

0.3 in

f = 0.4 mm/rev 0.02 in/rev

v c = 250 m/min 1,000 in/min

MACHINING AREA OF THE VL 3 DUO:

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: 100 mm (4 in) in diameter, spindle ﬂ ange to DIN 55026, size 6

+ Motor spindle with DirectDrive for minimum run-up times, maximum true running and diameter tolerances

+ Maximum torque over large range of speeds –baseline spindle speed: 1,408 rpm (at 100% duty cycle)

Highly productive machining of chucked parts with a diameter of up to 150 mm (6 inches) with minimum space requirements

Maximum precision

Machine base made of MINERALIT® polymer concrete, machine weight 10,000 kg, 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.

Maximum 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 requirement

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

+ Water-cooled motor spindle for maximum thermal stability

TECHNICAL DATA

Travel distance, X (machining stroke)/ Y (optional)/Z

Main spindles (2x) – Standard

» Power rating, 40%/100%

» Torque, 40%/100%

» Speed, max. rpm 5,000

» Spindle ﬂange to DIN 55026 Size 6

» Spindle bearing dia., front

100 4 High torque spindle – Option

» Power

» Torque, 40%/100%

» Speed, max.

Turrets (2x)

» Turret tool positions Qty 12 Rapid-traverse rate, X/Y/Z

MODULAR CUSTOMIZED SOLUTIONS

VLC pick-up turning machines – more than just turning

Various manufacturing technologies can be used ﬂexibly on these machines. In addition, they are extremely compact and have powerful drive units in their spindles and axes, which ensure they have plenty of capacity at all times. The great ﬂexibility of the equipment and powerful working spindles are supplemented by the integrated automation solution using pick-up spindles.

The machining area in VLC machines can be conﬁgured ﬂexibly. For the turning process, the twelve tool positions in the tool turret can be equipped with conventional and driven tools.

TECHNICAL DATA

Tool turret (driven as an option)

TECHNICAL DATA

VSC CUSTOMIZED SOLUTIONS

VSC – Multi-functional production centers

Machining + automation + measuring: The machines of the VSC Series are conﬁgured for individual production requirements. Their patented design guarantees the shortest travel times between the pick-up station and the machining area, reducing idle times The MINERALIT® polymer concrete machine base and the twin-wall construction have an excellent vibration damping effect and offer outstanding thermal stability.

Measuring station

Energy container Automation

TECHNICAL DATA

Hydrostatic guideway (standard)

Machine body made of MINERALIT® polymer concrete

Working spindle

Pick-up station

THE EMAG TURRET

The high-speed 12-station disk-type turret features very short swiveling times. Driven tools can be used on all twelve turret stations for drilling or milling operations. The EMAG turret gearbox combines high speeds with high capacity while requiring minimum ﬂ oor space.

+ Very high speed

– Very short swiveling times

– High speeds when using driven tools

+ Very high capacity

– Very small design with high torque

+ Very high precision

– Turret ﬁrmly embedded in the machine base = High rigidity

– Very high degree of repeat accuracy when indexing from tool position to tool position

+ Very high availability

– Inured to collisions, owing to the use of torque motors

– No raising of the turret for swiveling. This means that no chips or dirt can get into the turret.

VSC MULTI-SPINDLE MACHINES

VSC DUO – the twin-spindle machine for sequential operations

The VSC DUO principle offers a highly efficient solution for the machining of medium to large numbers of parts on a minimal footprint. The work areas are completely separated. This allows the axes to be programmed independently of each other. This makes it possible to realize sequential operations in one machine.

TECHNICAL DATA

TURRET

Both turrets accommodate not only stationary turning tools but also driven drilling and milling tools. This allows for either identical or different operations to be carried out in the two spindles:

+ After the ﬁrst set of operations have been carried out on the workpiece, using the ﬁrst spindle, the back of the component is machined in the second one; or the second spindle could be used to machine the workpiece in the same clamping position.

+ Two workpieces can also be machined with identical operational sequences.

VSC 250 DUO: Separate, extremely sturdy machine bodies made of MINERALIT® polymer concrete; the two overhead slides are independently programmable.

Machines shown with

VSC MULTI-SPINDLE MACHINES – TWIN MACHINES

High-speed turning machine for large-scale production

Over the years, EMAG has developed vertical turning machines that load themselves by moving the main spindle and performing various operations in a single clamping operation. In addition, there is a consistently symmetrical slide and machine structure for thermostable production. The VSC 160 TWIN is one of the fastest turning machines on the market for components up to 130 mm in diameter.

SIMULTANEOUS MACHINING

+ A single machining area with two working spindles

+ Simultaneous machining of two workpieces with identical operational sequences

+ Machining operations for workpiece diameter and length can be corrected for each working spindle individually

HIGHLY DYNAMIC, PRECISE AND RELIABLE –THE VSC 160 TWIN

+ The working spindle with hydrostatic bearings in the Z-axis ensures outstanding component quality and a high tool service life for soft and hard machining operations.

+ Closed, thermosymmetrical structure with machine base made of vibrationdamping MINERALIT® polymer concrete.

+ Good chip ﬂ ow thanks to the vertical design » Low-wear guiding elements

+ Cooling system for spindle motor, machine body, spindle, and turret

+ Turret for 2 x 4 tools

TECHNICAL DATA

TURNING MACHINES SHAFT PARTS FOR

VT MODULAR SOLUTIONS

Fast processes are required for machining large quantities of shafts. Both the machining process and the loading and unloading processes must be completed extremely quickly. The VT 2 and VT 4 machines are guaranteed to achieve the maximum performance you require.

Four axes, short distances, and a powerful main spindle – these are the strengths of the VT Series. The full effect of these can be felt, in particular, when machining large quantities. A key factor is the machining of parts from two sides. This greatly reduces the machining time. Two tool turrets, each with eleven tool positions which can be equipped with turning tools or driven tools, ensure machine ﬂ exibility.

AUTOMATION SEQUENCE

SIEMENS 840D SL NOW AVAILABLE

THE BENEFITS

+ The standard machine comes prepared (“tunnel”) 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

The gripper in turret 1 takes the 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, transports it to the ﬁnished parts storage area and deposits it there.

WORKPIECE CHANGEOVER TIME 6 SEC.

THREE KEY SUCCESS FACTORS

+ Reduced machining times due to four-axis machining

+ Shorter idle times with simultaneous loading and unloading of components

+ Highly productive shaft manufacturing thanks to integrated automation

Workpiece

VTC MODULAR CUSTOMIZED SOLUTIONS

VTC machines are available in either a single spindle or DUO version.

With a DUO version, this single machine operates like two four-axis turning machines, and offers a variety of machining technologies in its two stations. These machines are increasingly being converted into multifunctional production centers that include ﬁnishing operations such as cutting to length and centering. These operations prepare the parts for additional four-axis turning or more processes downstream. All of this is completed in a fully automated cycle on a single machine.

The spindle motor, main spindle, tool turret and electrical cabinet are all ﬂ uid-cooled. With their great power, high spindle speeds and sturdy turrets, the machines of the VTC Series are highly productive turning centers for shaft machining. In addition to workpiece grippers, every turret can be equipped with stationary turning tools or driven drilling and milling tools. Furthermore, the machining area can be ﬁtted with additional technology modules if required.