EMAG NEWS USA -- 01-2017

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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)

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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.

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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.

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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

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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.

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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

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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.

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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

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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

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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.

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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