EMAG NEWS USA February 2019

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Manufacturing Systems for Precision Metal Components

YOUR PARTNER FOR MEDICAL DEVICE MANUFACTURING! Precision is crucial in the medical device manufacturing industry. When you’re looking for production equipment, team up with EMAG, the manufacturer who values accuracy as much as you do. At EMAG, precision is always the main focus when designing our machines – From turning, grinding and also, Electro-Chemical Machining, EMAG offers a comprehensive line of manufacturing equipment to support your medical device manufacturing needs.

The EMAG PTS Precise Electro-Chemical Machining ((P)ECM) series is the perfect solution for precision machining in medical device manufacturing.

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EMAG NEWS

THE PROCESS

FUNCTIONAL PRINCIPLE

Tool (Cathode)

Electrolyte Solution

Power Source

Workpiece (Anode)

Precise Stent Manufacturing

High-Quality ArtiďŹ cial Hip Joints

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Manufacturing Systems for Precision Metal Components

MODERN GRINDING SOLUTIONS FOR MODERN MOBILITY CONCEPTS Shuttle automation for supply and removal of parts

One of the main characteristics of modern mobility concepts is that they blur or even eliminate borders to develop new ideas for the future of mobility.

Probe External grinding spindle Rotating dressing roll Working spindle

Today’s modern transmissions are smaller and lighter than they were in the past, but they are still required to have more gears – which means more gear wheels and gear components. Our new EMAG grinding systems are optimized to machine these and other modern powertrain and engine components – while still maximizing their flexibility.

Internal grinding spindle 12-tool turret for (hard) turning tools (optional Lifetool turret) NC controller

When you work with EMAG, you’ll have access to our engineers throughout the design process, and with their experience we can ensure maximum component quality, minimized cycle times and the lowest cost per piece. The VLC 200 GT is a great example of this with its flexible machining area and the ability to turn and grind on one machine.

Machines shown in trade show format

PMD 2

SN 204

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Machining of automotive crankshafts with a maximum length of 28 in

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Non-round grinding of camshafts

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Simultaneous oscillating / grinding with independent grinding units

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External round and non-round machining is possible

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X-axis drive system with anti-backlash linear motor

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Maximum of three grinding wheels (B-axis)

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Workpiece headstock with direct drive

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Hydrostatic ball screw drive and hydrostatic guideway in the X-axis

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Hydrostatic guide track (X-axis)

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Integrated measuring system

Compact design reduces machine footprint

Precision Crankshaft Grinding

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Grinding of Camshafts and Cam Pieces

EMAG NEWS

Short, flat surfaces are typically turned to finish, while geometric elements with high quality requirements (ex. for ripple) can be pre-turned and ground. The combination machining available on this system allows tools to be customized to fit the specific machining tasks, allowing us to easily achieve surface values with an average peak-to-valley height Rz of less than 1.6 µm.

TECHNICAL DATA Chuck diameter

8 in

Swing diameter

11 in

Max. workpiece diameter

6 in

Max. workpiece length

4 in

Travel distances, X (total stroke from pick-up to turret) / Z Loading time (depending on clamping device)

67 / 10 in 6 – 10 sec.

Main spindle » Power rating, 40% / 100% duty cycle » Torque, 40% / 100% duty cycle » Max. number of revolutions » Spindle bearing diameter, front

30 / 24 hp 184 - 149 ft-lb 3,000 rpm 4 in

PERFECT FOR ALUMINIUM OXIDE AND CBN GRINDING EQUIPMENT

HG 204 / HG 208

Cylindrical Grinding for the Mass Production of Precision Shafts

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Modular system for the cylindrical grinding of shafts with simple single-slide solutions and highly productive twin-slide solutions.

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Use of CBN or aluminium oxide grinding equipment (maximum diameter of 30 in)

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Integrated measuring for external diameter and longitudinal positioning

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Optional hydrostatic center drive for the simultaneous internal and external machining of hollow shafts 5

Manufacturing Systems for Precision Metal Components

VL 1 TWIN – THE PERFECT PRODUCTION PROCESS FOR PLANETARY GEARS, SUN GEARS, CAMS AND MORE! If you combine the productive TWIN approach with the simple to link TrackMotion automation system, you get the VL 1 TWIN line – one of the most compact, productive manufacturing solutions on the market for chucked parts with a maximum diameter of 3 in.

HIGH SPEED LINEAR MOTOR

Machine base made of MINERALIT® polymer concrete Linear motor (secondary component) in the X-axis Spindle unit (Z-axis) Slide unit (X-axis) Direct position measuring system in the Z-axis

The VL 1 TWIN line allows two components to be machined, on two sides in OP 10 / OP 10 and OP 20 / OP 02, minimizing cycle times to under 20 seconds for the entire process. With the overall low cost of the machine and the minimized cycle times, this system can significantly reduce the cost per piece.

OP 10 / OP 10 NC Shuttle Tool turret for 2 x 4 VDI30 or BMT45 tools Chip tray for wet and dry machining

Access to e-container and hydraulics

MACHINE 1 (OP 10 / OP 10)

Access to e-container and hydraulics

TrackMotion automation system

MACHINE 2 (OP 20 / OP 20)

The TrackMotion automation system links two VL 1 TWIN machines including the parts storage area.

Spindle

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Spindle

Parts storage area

EMAG NEWS

The two components are removed from the conveyor belt by the pick-up spindles (9.9 kW / 136 Nm), transported to the machining area and machined simultaneously in one clamping operation.

The diameter and length (X / Y direction) of the two components can be corrected independently of each other – a special feature of the VL 1 TWIN.

AUTOMATION INCLUDED

The TrackMotion automation system not only easily links multiple machines, but also replaces changers and conveyor belts. With their three-dimensional design, stacker pallets in the parts storage area provide a place to store a large number of workpieces, ensuring maximum autonomy.

TECHNICAL DATA

Planetary Gear

Sleeve

Workpiece ∅: 1.5 in Material: 20CrMoH

Workpiece ∅: 2 in Material: 21NiCrMo2

Max. workpiece diameter

3 in

Chuck diameter

6 in

Swing diameter

6 in

Max. workpiece length

3 in

Workpiece weight Travel distance, X / Z

2 lbs 24 / 8 in

Main spindle

12 SEC.

16 SEC.

» Power rating, 40% / 100% » Torque, 40% / 100% » Max. number of revolutions

VL 1 TWIN Workpieces

Flange Workpiece ∅: 2 in Material: CrNi1810

26 SEC.

Cycle Time*

Cam Workpiece ∅: 1.5 in Material: 100Cr6

9 SEC.

* 16 second cycle time, for a machining time of 32 seconds (two spindles)

Rapid-traverse rate, X / Z Tool stations CNC controller

13 / 12 hb 100 / 70 ft-lb 6,000 rpm 3,150 / 1,181 ipm 2 x 4 – VDI30 / BMT45 FANUC 31i with MANUAL GUIDE i

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Manufacturing Systems for Precision Metal Components

VM 9: TURNING CENTER FOR LARGE CHUCKED PARTS The VM 9 vertical turning center was designed to precisely and efficiently manufacture individual parts or small production runs for a variety of parts.

Depending on the desired tool interface (BMT or VDI), the tool turret features eight or 12 different tool positions, which can be equipped with driven tools to perform additional operations, such as drilling. Also included is an integrated part probe which guarantees quality and reliability (first part = good part).

These features ensure that the VM 9 is well equipped to achieve a wide variety of production tasks.

MAXIMUM WORKPIECE DIAMETER

18 IN

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EMAG NEWS

BENEFITS OF THE VM 9 +

Maximum Productivity » Dynamic axes decrease idle times and guarantees quick machining processes

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Simple Handling » All necessary service units are easy to reach

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Maximum Performance » Short workpiece travel distances

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High Surface Accuracy » Linear glass scales in all axes

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Ideal for the Production of Large Parts » Large main spindle, maintenance free spindle motors and rigid guideways

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Increased Workpiece Service Lives » MINERALIT™ polymer concrete machine base with six – eight times better damping properties than grey cast iron

TECHNICAL DATA Max. chuck diameter

18 in

Swing diameter over base

28 in

X-axis travel

15 in

Z-axis travel

20 in

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Manufacturing Systems for Precision Metal Components

EMAG – THE LEADER FOR OCTG (OIL COUNTRY TUBULAR GOODS) MACHINES! At EMAG, we offer customized solutions for the machining of a variety of oil field components. Our flexible machine concepts and integration of complete systems are perfect for the manufacturing of tube ends, couplings, tool joints, drill bits, rock bit cones and pump components. We also have high quality machining solutions for components in mobile hydraulics such as hydraulic cylinders and piston rods.

VL 6 / VL 8 / VL 10 The EMAG standard for the precise production of couplings 10

VLC 500 CM Complete coupling production on modular machines

VSC 400 CM / VSC 500 CM Vertical production centers

EMAG NEWS

ADVANTAGES OF EMAG MACHINES +

Modular, compact design

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Sturdy, vibration resistant MINERALIT™ polymer concrete machine base

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Powerful, direct-drive spindle motors

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Direct-indexing tool systems

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High-precision, preloaded linear roller guides

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Position feedback systems for constantly maintained precision

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Safe, wear resistant, maintenance free machining area

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Ideal chip ow conditions, falling downward out of the machining area

THE USC 27 / VLC 800 CM Coupling machining center 11

Manufacturing Systems for Precision Metal Components

HOUSTEX 2019 INVITATION

EUROPE

HOUSTON, TX

Salach Austraße 24 73084 Salach Germany Phone: +49 7162 17–0 Fax: +49 7162 17-4027 E-mail: info@salach.emag.com

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EMAG Milano S.r.l.

Via dei Mille 31 20098 San Giuliano Milanese (MI) Italy Phone: +39 02 905942-1 Fax: +39 02 905942-21 E-mail: info.milano@emag.com

NEWS 02/USA/02.2019 · © Copyright EMAG · Printed in USA

To learn more about our OCTG solutions and much more, visit us at Houstex 2019, February 26 – 28 in Houston, TX! Visit www.emag.com/houstex for more information.

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ASIA EMAG (China) Machinery Co., Ltd Building A3 & B7 Cangneng Europe & America Technology Park No. 8 Loujiang Rd. (N.) 215400 Taicang Jiangsu, China Phone: +86 512 5357-4098 Fax: +86 512 5357-5399 E-mail: info@emag-china.com

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www.emag.com

Subject to technical changes.

EMAG L.L.C. U.S.A. 38800 Grand River Avenue Farmington Hills, MI 48335 U.S.A. Phone: +1 248 477-7440 Fax: +1 248 477-7784 E-mail: info@usa.emag.com