REINECKER KARSTENS KOPP NAXOS-UNION KOEPFER LASER TEC ECM ELDEC
VISIT US! BOOTH 2321
Manufacturing Systems for Precision Metal Components
THE VM- AND VMC-SERIES – ECONOMICAL MANUFACTURING OF LARGE PARTS AND COMPLEX WORKPIECES Universality is the main feature of the VMC MT-series, which can be configured to suit almost any customer demand. The machines not only deliver the full range of technologies for turning, drilling and milling, but also offer various spindle and tool socket versions.
TECHNICAL DATA
VMC 300 MT
Chuck diameter
inch
12.5
Travel distance X / Z
inch hp
VMC 450 / VMC 600 / VMC 450 MT VMC 600 MT 19.5
25
13.5 / 19
25 / 19.5
30.5 / 20
64 / 97
64 / 97 / 113 / 142
97 / 142 / 125
Main drive »» Power rating, max. »» Torque, max.
ft-lb
435 / 634
435 / 634 / 738 / 1,069
634 / 738 / 1,880
»» Number of revolutions, max.
rpm
3,000 / 2,400
3,000 / 2,400 / 2,000
2,400 / 2,000 / 1,250
Turning diameter, max.
inch
12
17.5
23.5
Workpiece height, max.
inch
12
12
12
lb
661
661
1,102
Weight, max. (incl. clamping chuck)
THE VM 9 VERTICAL TURNING CENTER IS DESIGNED FOR THE MANUFACTURE OF LARGE, WIDELY VARYING PARTS The tool turret in the VM 9 can be created with between eight and twelve tool positions depending on the tool interface desired (BMT or VDI), and can also be equipped with driven tools to perform things such as drilling operations. The integrated probe ensures process reliability and guarantees consistently high workpiece quality (first part = OK part). These features make the VM 9 the perfect choice for efficiently performing a wide variety of production tasks. of production tasks.
TECHNICAL DATA Chuck diameter, max.
inch
Travel distance X / Z
inch
Main drive »» Power rating, max. »» Torque, max. »» Number of revolutions, max.
17.5
13 / 19.5
hp
66 / 111
ft-lb
431 / 730
rpm
3,000 / 2,400
Turning diameter, max.
inch
17.5
Workpiece height, max.
inch
12
lb
661
Weight, max. (incl. clamping chuck)
2
VM 9
EMAG NEWS USA
ADVANTAGES OF THE VMC PRODUCT FAMILY ++ MAXIMUM PRODUCTIVITY: Highly dynamic axes for short idle times and quick machining processes
++ HIGH SURFACE ACCURACY: Axis monitoring by rotary, indirect absolute encoders. All axes have an optional fully encapsulated linear glass scale
++ USER FRIENDLY: All the service units are easy to reach
++ IDEAL FOR HEAVY-DUTY MACHINING:
Generously dimensioned main spindle, maintenance-free spindle motors and rigid guideways
++ MAXIMUM PERFORMANCE: Minimized transportation times
++ EXTENDED TOOL LIFE: Machine body is made out of MINERALIT® material which has six to eight times better damping properties than gray cast iron
Machine body
X Z
Z-axis
X-axis
C Turning / milling spindle
VM 9 axis design
Main spindle NC control
Design of the VM 9
The use of a tool magazine allows for the production of parts with very complex geometries, making the creation of a wide variety of workpieces possible and the VMC 450 MT turning and milling machine a genuine productivity center. Various tool magazines, starting with 40 tool positions, are available.
Drilling and milling operations can also be completed by driven tools in the turret.
3
Manufacturing Systems for Precision Metal Components
VSC 400 CM, VSC 400 DUO CM AND VSC 500 CM – VERTICAL PRODUCTION CENTERS The VSC 400 CM, VSC 400 DUO CM and VSC 500 CM vertical production centers complete-machine coupling sleeves with any thread type found in the OCTG sector. The cornerstone of the VSC-series is a robust machine base created with MINERALIT® polymer concrete. The DUO features two separate machining areas, each equipped with an independently programmable overhead slide. Also featured in each machining area is a programmable EMAG disk-type turret mounted to the front wall. This division allows for the two spindles to either be assigned an identical task or to be on two different machining cycles, based on customer demand.
4
MACHINING OF COUPLING SLEEVES ON THE VSC 400 CM AND VSC 400 DUO CM
MACHINING OF COUPLING SLEEVES ON THE VSC 500 CM
Nominal diameter
Nominal diameter
With standard chuck
2 ⅜“ – 9 ⅝“
With standard chuck
6 ⅝“ – 13 ⅜“
With indexing chuck
2 ⅜“ – 7“
With indexing chuck
4 ½“ – 8 ⅝“
EMAG NEWS USA
TECHNICAL DATA
VSC 400 CM / VSC 500 CM VSC 400 DUO CM
Chuck diameter
inch
17.5
19.7
Swing diameter
inch
17.7
20.5
X-axis / Z-axis travel
inch
33.5 / 12.4
39.4 / 15.7
Workpiece diameter, max.
inch
10.6
14.6
»» Standard chuck
inch
12.6
13.4
»» Indexing chuck
inch
10.2
13.4
Qty
1/2
1
»» Spindle flange to DIN 55 026 Size
11
11
rpm
3,400 / 4,000
500
hp
80 / 95
90
»» Torque, max.
ft-lb
900 / 553
2,655
»» Full power at
rpm
470 / 900
175
ipm
1,772 / 1,181
1,772 / 1,181
lbf
2,473 / 2,473 / 4,047 / 4,047
2,473 / 2,473
inch
2.0 / 1.6
2.0 / 2.0
Workpiece height, max.
Main spindle »» Number of spindles
»» Speed Main drive »» Power rating, max.
Feed drive »» Rapid-traverse rate X / Z »» Feed force X / Z »» Ball screw X / Z diameter
5
INVITATION TO HOUSTEX 2017 EMAG offers machines and complete manufacturing systems for a variety of industries including oil field, automotive, aerospace, energy and more! When you work with EMAG in any of these industries you can plan on working with a partner who is committed to the highest quality and reliability standards in the use of cutting-edge technologies. We would like to invite you to experience our innovative manufacturing solutions live at Houstex 2017. We'll have our VL 4 modular vertical turning machine on display, and our industry experts available to discuss your production challenges and available EMAG solutions. Visit us in booth 2321 at the George R. Brown Convention Center, February 28 – March 2, 2017. For your complimentary entry ticket, register at houstex.emag.com.
6
1641
1740
2441
2540
2541
2640
2641
2740
1639
1738
2439
2538
2539
2638
2639
2738
2634
2635
2734
2537
1535
1635
1734
1735
1935
2135
2035
2335
2435
2535
2735
HALL B
1527
1627
1927
1725
1521
2031
2725
2824
2027
2727
2826
2827
2723
2822
2823
2922
2721
2820
2821
2920
2817
2916
2815
2914
2025
1721
1920
1921
1614
1610
1509
1608
1503
2321
1611
2521
2421
2717
2315
1710
1609
1706
1603
1702
1703
2621
2118
1615
1715 1511
2121
2021
1917 1515
2124
1913
2112
1911
2110
1909
2108
1903
2003
VISIT US!
2113
2103
2312
2715
2513
2415
2303
2403
2502
2503
2814
2613
2603
2703
Feb. 28 – Mar. 2 ENTRANCE
BOOTH 2321
ENTRANCE
7
Manufacturing Systems for Precision Metal Components
ELECTRO-CHEMICAL MACHINING (ECM) WITH UP TO FOUR AXES – NEW DESIGN FREEDOM FOR WORKPIECES The ability to produce components with complex 3D geometries out of high strength materials is very demanding on machining technology. The PT-Series of machines from EMAG use electro-chemical technology with up to four axes to machine even very intricate 3D components with no thermal effects. With this technology, feed speeds of up to five mm/min are achieved for roughing, while full area and parallel machining of 20 - 30 components allow for maximum efficiency to be achieved. These machines are so precise, that during production precision extends below 20 micrometers. An additional benefit is that ECM machines have been developed to have a very long tool life compared to traditional cutting processes. This process also eliminates the problem of micro-cracks as found in eroding which would adversely affect the stability of the component, a very important factor for high performance press tools. Non-contact: Since the materials are not heated, the component will not experience any negative effects to its micro structure.
PRODUCTIVITY COMPARISON: EDM VS. ECM ++ For prototypes, the advantages of EDM are seen in the lower equipment complexity and equipment costs.
++ As quantities increase however, the ECM process is beneficial
Productivity
because the tool suffers zero wear, and will therefore last much longer.
8
EDM Sink Erosion
EDM Sink Erosion
ECM/ PECM
ECM/ PECM
Prototypes
Very small batch size
ECM/ PECM
EDM Sink Erosion Medium series
ECM/ PECM
EDM Sink Erosion Large series
EMAG NEWS USA
MACHINING DIES
PECM cathode
PECM process step 1
PECM process step 2 (final)
MARGINAL ZONE ANALYSIS: EDM VS. ECM Marginal zone characteristics of the EDM process:
Nickel based alloy
++ Mechanical grain size deformation
Use
Die
Material
INOX
Surface Finish
Ra 0.25
OTHER POSSIBLE USES FOR 3D PRECISE ELECTRO-CHEMICAL MACHINING TECHNOLOGY
++ Thermally affected marginal zone, if necessary with white marginal zone
++ Formation of micro-cracks in the material (red) 20 µm
++ Negative effect on the material structure resulting in a possible reduction in the service life of the workpiece
Wire-eroded sample
Marginal zone characteristics of the ECM process:
Blisk
Nickel based alloy
Gear wheel
Injection molding
Application
PECM
PECM
PECM
Material
Nickel alloy
AISI 304
AISI H13
Tolerance
+/- 0.05 mm
+/-0.02 mm
+/-0.02 mm
++ Material grain size structure unaffected ++ No negative effect on the marginal zone ++ No formation of micro-cracks
PECM
9
Manufacturing Systems for Precision Metal Components
EMAG SERVICES – A COMPLETE PACKAGE FROM A SINGLE SOURCE Maximum productivity isn't just dependent on technology, it also requires good service to ensure minimum downtimes, short reaction times and the long service life of the machine. The efficiency of a system is determined by three primary factors: its availability, its output and the quality of the workpiece it produces. Our service team acknowledges the importance of these factors and is focused on providing services to help our customers remain successful. We help our customers plan their production, continue to develop the process if requested, monitor the procedures, record the system operating data, maintain all necessary components, correct undesirable discrepancies and repair defective equipment. Our objective is to ensure the maximum efficiency of your system, ensure long service life and maintain efficient production processes.
MACHINERY SERVICE USED MACHINERY / RETROFITTING
CLAMPING DEVICE SERVICE
FULL SERVICE
PRODUCTION SUPPORT TRAINING
10
EMAG NEWS USA
ACTIVE GLOBALLY Our service teams are available worldwide. As an EMAG customer, you benefit from the speed and global networking that only our employees have access to thanks to our global, comprehensive knowledge pool. This expertise ensures perfectly maintained and adjusted machines.
THREE SERVICE EXAMPLES – MORE BENEFITS THAN YOU CAN IMAGINE From exclusive machine service, to training and our technical helpline - we customize our services to fit your needs! Here are three examples of available service:
1. EMAG ACADEMY
2. COOPERATIVE SERVICE
3. RETROFIT
Your workforce is key to your success, and can give you a major advantage over your competitors. These staffers control, inspect and maintain your system, and this maintenance has an enormous effect on the entire process. At the EMAG Academy, our center for further education, we have experienced trainers who can explain the technology and machine operation in practical terms. The knowledge and demonstrations provided to you by the Academy will provide the basis for your innovative strength and growth.
The customer's expertise and experience, supplemented with the detailed knowledge of the EMAG experts is key to greater efficiency and decreased costs. This cooperation makes it possible to achieve the perfect maintenance solution. Preventive servicing and routine maintenance allows you to keep your costs under control and to maintain consistently high availability. Success through partnership!
Completely and partially reconditioned machines are an economical alternative to purchasing a new machine. Having the retrofit process completed by EMAG gives you the benefit of the expertise and experience of the original equipment manufacturer. With retrofit, your EMAG machine will be restored to like new condition. Our retrofit specialists recondition or replace mechanical, electrical, hydraulic, control and coolant supply components. The production process benefits from a costefficient machine with fast machining times and a stateof-the-art control unit. These machines may be used, for example, in times where capacity is short and comply with all modern environmental and safety regulations.
11
Manufacturing Systems for Precision Metal Components SALACH Austrasse 24 73084 Salach Germany Phone: +49 7162 17-0 Fax: +49 7162 17-4820 E-mail: info@salach.emag.com
MUNICH Zamdorferstrasse 100 81677 München Germany Phone: +49 89 99886-250 Fax: +49 89 99886-160 E-mail: info@muenchen.emag.com
SWEDEN Glasgatan 19B 73130 Köping Sweden Phone: +46 221 40305 E-mail: info@sweden.emag.com
POLAND ul. Prusa 9F / 1 50-319 Wrocław Poland Phone: +48 728 389 989 Fax: +48 601 371 353 E-mail: info@poland.emag.com
FRANKFURT Martin-Behaim-Strasse 12 63263 Neu-Isenburg Germany Phone: +49 6102 88245-0 Fax: +49 6102 88245-412 E-mail: info@frankfurt.emag.com
AUSTRIA Glaneckerweg 1 5400 Hallein Austria Phone: +43 6245 76023-0 Fax: +43 6245 76023-20 E-mail: info@austria.emag.com
HUNGARY Gerenda u. 10. 1163 Budapest Hungary Phone: +36 30 9362-416 E-mail: lbujaki@emag.com
TURKEY Sanayi Cad. No.: 44 Nish İstanbul Sitesi D Blok D: 155 Yenibosna – Istanbul Turkey Phone: +90 532 694 54 44 E-mail: ckoc@emag.com
LEIPZIG Pittlerstrasse 26 04159 Leipzig Germany Phone: +49 341 4666-0 Fax: +49 341 4666-114 E-mail: info@leipzig.emag.com
DENMARK Horsvangen 31 7120 Vejle Ø Denmark Phone: +45 75 854854 Fax: +45 75 816276 E-mail: info@daenemark.emag.com
CZECH REPUBLIC Lolkova 766 103 00 Praha 10 – Kolovraty Czech Republic Phone: +420 731 476070 E-mail: mdelis@emag.com
EUROPE
AMERICA
ASIA
ZETA EMAG Srl Viale Longarone 41/A 20080 Zibido S.Giacomo (MI) Italy Phone: +39 02 905942-1 Fax: +39 02 905942-21 E-mail: zetaemag@emag.com
EMAG L.L.C. USA 38800 Grand River Avenue Farmington Hills, MI 48335 USA Phone: +1 248 477-7440 Fax: +1 248 477-7784 E-mail: info@usa.emag.com
NODIER EMAG Industrie 2, Parc des Fontenelles 78870 Bailly France Phone: +33 130 8047-70 Fax: +33 130 8047-69 E-mail: info@nodier.emag.com
EMAG MEXICO Maquinaria EMAG Mexico S de RL de CV Av. Hercules 301 Nave 1 Poligono Empresarial Santa Rosa 76220 Santa Rosa Jauregui, Queretar Mexico Phone: +52 (442) 291 1552 E-mail: swieland@emag.com.mx
EMAG (China) Machinery Co., Ltd Building 3, Cang Neng Europe & American Technology Park No. 8 Lou Jiang Rd. (N.) 215400 Taicang Jiangsu, China Phone: +86 512 5357-4098 Fax: +86 512 5357-5399 E-mail: info@emag-china.com
NEWS -EN/01.2017 · © Copyright EMAG · Printed in the USA
EMAG Salach GmbH
Market Companies
EMAG (UK) Ltd. Chestnut House Kingswood Business Park Holyhead Road, Albrighton Wolverhampton WV7 3AU Great Britain Phone: +44 1902 37609-0 Fax: +44 1902 37609-1 E-mail: info@uk.emag.com EMAG OOO ul. Akademika Chelomeya 3/2 117630 Moskau Russia Phone: +7 495 28709-60 Fax: +7 495 28709-62 E-mail: info@russia.emag.com
EMAG DO BRASIL Ltda. Edifício Neo Corporate Offices, CJ 1503 Rua Enxovia, 472 04711-030 São Paulo SP, Brazil Phone: +55 11 38370145 Fax: +55 11 38370145 E-mail: info@brasil.emag.com
EMAG (Chongqing) Machinery Co., Ltd. No. 10th Lailong Road Yongchuan District 402160 Chongqing China Phone: +86 23 49783399 Fax: +86 23 49783388 E-mail: info@emag-china.com TAKAMAZ EMAG Ltd. 1-8 Asahigaoka Hakusan-City Ishikawa Japan, 924-0004 Japan Phone: +81 76 274-1409 Fax: +81 76 274-8530 E-mail: info@takamaz.emag.com EMAG INDIA Pvt. Ltd. Technology Centre, No. 17/G/46-3, Industrial Suburb, 2nd Stage, Yeshwantpur, Bangalore 560022 India Phone: +91 80 42544400 Fax: +91 80 42544440 E-mail: info@india.emag.com
www.emag.com
Subject to technical changes.
ZETA EMAG Srl, Sucursal en España Pasaje Arrahona, no 18 Polígono Industrial Santiga 08210 Barberà del Vallès (Barcelona) Spain Phone: +34 93 7195080 Fax: +34 93 7297107 E-mail: info@emh.emag.com
EMAG Korea Ltd. Rm204, Biz center, SKn Technopark, 124 Sagimakgol-ro, Sangdaewon-dong, Joongwon-gu, Seongnam City Gyeonggi-do, 462-721 South Korea Phone: +82 31 776-4415 Fax: +82 31 776-4419 E-mail: info@korea.emag.com