EMAG NEWS USA - April Issue

REINECKER KARSTENS KOPP NAXOS-UNION KOEPFER LASER TEC ECM ELDEC

Manufacturing Systems for Precision Metal Components

MANUFACTURING SYSTEMS FOR CHUCKED PARTS – SYSTEMATICALLY SUCCESSFUL The more sophisticated the component, the more complicated the production solution? Not at EMAG: our specialists develop manufacturing systems that score with simple interlinking, speed and flexibility.

The characteristic that guarantees the success of this system is the modular design of the new EMAG pick-up machines. These machines ensure economical processes with these three central benefits:

1.

Whether turning, milling or drilling – based on the modular design, every individual machine can be perfectly configured for the respective operation.

2.

Conveyor belts or shuttles transport the parts between machines resulting in decreased transportation times. Transport distances are short which allow the workpieces to flow fast.

3.

Every operation and the degree of automation featured in the machines is customizable based on the customer demand. This means that the manufacturing system can always be perfectly adjusted, even with increasing quantities or changed component requirements.

In short: EMAG manufacturing systems benefit from their modular machine design, simple automation and flexible configuration.

2

EMAG NEWS USA

EXAMPLE: MANUFACTURING SYSTEM FOR GEARS QUESTIONS & ANSWERS ++ TURNKEY?

With EMAG, the technology, automation and process development all come from a single source. Ultimately, this provides you with a complete solution that features short lead times and fast production guaranteed.

++ OPTIMIZED?

We coordinate the manufacturing systems, peripheral machines and automation systems so they work perfectly with one another.

++ PRODUCTIVE?

The complete system developed by EMAG benefits from simple automation systems, optimized interfaces and short workpiece transport distances. This ensures that the full process can be started quickly and will remain economical over time.

++ EASY MAINTENANCE?

We use a number of identical components within the machine making them easy to replace.

The manufacturing system also benefits from short re-tooling and maintenance times.

++ LOTS OF PLANNING?

A contact at EMAG takes on the central project work and makes your overall planning process easier with their experience and system expertise.

LINE CYCLE TIME:

25 SECONDS

Peter Loetzner President/CEO EMAG L.L.C. "We act as a system supplier and create a complete manufacturing system for our customer - from the individual machine to the machining processes and the automation."

3

INVITATION TO EASTEC 2017 The EMAG Group covers the entire spectrum of machining processes in the metalworking industry, with our expertise including turning, milling, grinding, gear hobbing, heat shrink assembly, ECM / PECM, laser welding, induction hardening and more. The leader in inverted vertical pick-up lathes, EMAG has integrated its pick-up principle into a wide array of technology-specific machines offering world-class manufacturing with a minimal footprint, short chip-to-chip times and top quality. We would like to invite you to experience our innovative manufacturing solutions live at Eastec 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 1748 at the Eastern States Exposition in West Springfield, MA for Eastec 2017.

For your complimentary entry ticket, register at eastec.emag.com.

4

1762

1654

1662

1468

1462

1266

1158

1058

1067

1753

1749 1747

1743

1737

1652

1648

1644

1638

1742

1055

1734

1348

1344

1248

1244

1148

1235

1142 1140

BOOTH 1748

1051

1044

1047

1043

1706

1723

1719

1713

1711

1705

1628

1626 1624

1620

1614

1612

1606

1420

1426

1236

May 16 – 18 1052

1712

1406

ENTRANCE

1328

1243 1241

1152

1720

1727

1434

VISIT US!

1251

1726

1634

1450

1254

1257

1063

1748

1454

1262

1164

1754

1228

1231 1136

1037

1035

1128

1028

1031

1206

1227

1132

1034

1218

1027

1118

1022

1021

1106

1018

1017

1005

5

Manufacturing Systems for Precision Metal Components

TRACKMOTION – TRANSPORTING PARTS AS IF THEY WERE ON RAILS TrackMotion is a new development combining the previous concept of conveyor belts, pick-and-place units and changers in one single automation solution.

Put in simple terms, with TrackMotion a so-called TransLift unit runs on a rail system (hence the name “Track”) through the machines. The TransLift grips the parts at different heights, while also positioning and turning the workpiece over. Multiple machines can be linked to each other very easily using a TrackMotion system. Multiple TransLift units can be used for shorter cycle times, adding to the speed the TrackMotion system is already equipped with.

The machines are linked via TrackMotion, which handles both picking and placing the workpieces and turning them over.

A parts storage facility supplies the raw parts (storage capacity up to 400 parts, depending on the workpiece geometry).

Linking three VL machines using the EMAG TrackMotion system.

6

EMAG NEWS USA

THE BENEFITS OF TRACKMOTION ++ Minimal set-up time – TrackMotion is ready for use as soon as the workpiece height and part diameter have been entered.

++ Great reliability due to its simple, sturdy design. ++ Flexible system – multiple TransLift units (pickand-place units and changers) can be installed on a single rail system.

++ The workpieces are positioned and turned over in one cycle.

++ Space-saving since the whole TrackMotion system is installed behind the machines.

++ Measuring equipment, marking systems,

cleaning machines and lots of other functions can be integrated.

++ Easy to service – TrackMotion is easily accessible from all sides.

++ Short part transport times with horizontal travel speeds of 150 m/min and 25 m/min vertically.

EMAG TrackMotion for the simple interlinking of multiple machines.

THE VL-SERIES: A SOLUTION FOR ANY COMPONENT SIZE

TECHNICAL DATA Chuck diameter, max.

Workpiece diameter, max.

Workpiece length, max.

X-axis travel Z-axis travel Y-axis travel (optional)

VL 2

VL 4

VL 6

VL 8

mm

160

260

400

500

mm

100

200

300

400

mm

150

200

250

300

mm

700

740 29

880

34.5

995

mm

375

400

480

580

mm

± 50

± 30

± 30

± 30

kW

19,5 / 12,5

27 / 18

39 / 28

44 / 34,5

Nm

75 / 48

303 / 202

460 / 320

775 / 600

1/min

6.000

4.500

3.100

2.850

inch inch inch inch inch inch

6.5

4 6

27.5 15

±2

10

8 8

15.5 ±1

15.5 12

10

19

±1

19.5

15.5 12

turdy machine construction, dynamic axes and S easy to operate – these are the features of all vertical VL turning machines. For larger components, in addition to the VL 2 and VL 4, the VL 6 (max. workpiece diameter 12 inches, max. workpiece length 10 inches) and VL 8 (max. workpiece diameter 15.5 inches, max. workpiece length 12 inches) are also available.

39

23

±1

Main spindle »» Power rating at 40% / 100% duty cycle »» Torque at 40% / 100% duty cycle »» Speed, max.

hp

ft-lb

rpm

26 / 17

55 / 35 6,000

36 / 24

223 / 149 4,500

52 / 38

339 / 236 3,100

59 / 46

572 / 443 2,850

7

Manufacturing Systems for Precision Metal Components

PECM SYSTEMS FROM EMAG – FOR EVEN MORE PRECISION Electro-checmical machining (ECM) from EMAG creates highly efficient production processes. With our "PECM" process, our experts have made this technology even more precise.

During the ECM process, metal is removed through electrolysis: the workpiece becomes the positive anode and the tool is the negative cathode with an electrolyte solution flowing between the two. The PECM process, with the "P" standing for "Precise", was created to allow this technology to provide even more precision. Throughout this process, a mechanical oscillation movement assists in the electrolyte exchange which superimposes the feed movement. This allows PECM systems, such as the PO 900 from EMAG, to produce extraordinary surface quality and accuracy. In addition, the variable oscillator and the zero point clamping system ensure that the production process is efficient.

In conclusion: PECM technology is a low-wear, very precise and efficient manufacturing process.

Tool

Pulsing current

Tool

Pulsing current

Workpiece

Tool Electrolyte solution

Tool Electrolyte solution

AN EFFICIENT PROCESS Thanks to a synchronous PECM lowering process , both sides of the blade are machined simultaneously.

Ra 0.2 (DEPENDING ON MATERIAL)

8

EMAG NEWS USA

ELECTRO-CHEMICAL DRILLING Electro-Chemical drilling produces absolutely no burr or drilling caps – a massive advantage for opening up cavities, for example.

++ Simpler: Drilling produces

no burr or drilling caps. This means no deburring – a crucial advantage in the production of difficult to machine components.

++ More stable: In the ECM

process, the material is not heated, which means there is no negative effect to the components microstructure and no micocracks.

++ Faster: The ECM process

can drill 20 or more boreholes at the same time. Two of the major benefits of the ECM process is that it guarantees short cycle times and lean processes, with a feed rate of up to 5 mm/min.

++ Flexible: This process is

perfect for both hard and soft machining and the feed rate is not affected by the material hardness.

++ Lower cost: Throughout this process, the tool experiences almost no wear allowing for a very long service life for the drilling cathodes, even when using hard materials.

ELECTRO-CHEMICAL DRILLING - PERFECT MACHINING DONE FAST! High speeds, turbo charging and direct injections: the requirements for pistons and camshafts are becoming more demanding, while the components themselves become increasingly complex. This is where electro-chemical drilling can showcase its strengths.

The production of pistons with coolant passages also benefit.

9

Manufacturing Systems for Precision Metal Components

ELC 160 LASER WELDING MACHINE – LIGHTWEIGHT DESIGN WITH LASER WELDING Laser welding is a key technology in the flexible production of weight-optimized vehicle components.

Laser welding not only delivers excellent component quality, but also helps to significantly reduce the overall weight and thus lower fuel consumption.

Laser-precision productivity The ELC 160 is ideally prepared for series production thanks to its integrated automation. Precise beam control combined with automatic loading and part testing ensures short cycle times and uniformly high workpiece quality.

Compared to a CO2 laser, the solid-state laser used delivers the same optical output at considerably lower energy costs.

100 90

– 50 %

80

Energy savings

70 60 50 40 30 20 10 KW

0 CO 2 laser

Output

10

Waste heat

Solid-state laser Cooling capacity

In the production of this transmission shaft, the shaft, annulus gear and disc carriers made by forming techniques are joined by laser welding.

EMAG NEWS USA

PERFECT CONNECTION

MANUAL OR AUTOMATIC LOADING

THE LATEST TESTING TECHNOLOGY

Precision mechanical engineering and the latest laser technology ensure maximum, uniform quality.

The ELC 160 is perfect for universal use including manual loading or in complex manufacturing systems.

Workpieces are checked by ultrasound after each operation to guarantee uniformly high quality.

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/04.2017 · © 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