Modern (hybrid) drive units are real miracles of engineering.
This complex interaction of diverse components demonstrates everything that is possible with internal combustion engines. A study, “The Change in Drive Units” performed by the VDMA predicts, this drive system will still be dominant in 2030, primarily in the form of hybrid systems. Given the complex range of components and the high unit volumes required, flexible manufacturing solutions are necessary. The next few pages will go into detail on the perfect production solution for the hard machining of these components.
» Soft Machining (Turning)
Machines: VL 3 DUO
» Gear Hobbing of Gear Wheels
Machines: HLC 150 H
» Hard Finishing (Hard Turning/Grinding)
Machines: VLC 200 GT
» Joining and Laser Welding
Machines: ELC 160 / ELC 160 HP
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» Soft Machining (Turning) of the Shaft
Machines: VT 2 / VT 4 / VTC 100 / VTC 200
» Gear Hobbing of Gear Wheels
Machine: HLC 150 H
» Hard Finishing (Hard Turning/Grinding)
Machines: VTC 100 GT / VTC 315 DS / HG 204 / HG 208
» Turning Rotor/Stator Carriers
Machines: VL 6 / VL 8
» Electrochemical Deburring
Machine: CI 400
» Turning
Machines: VT 2 / VT 4 / VTC 100 / VTC 200
» Hard Finishing (Hard Turning / Grinding)
Machines: VTC 100 GT / VTC 315 DS
Too often, finishing processes are thought of in multi-machine concepts – in the end, people rely entirely on the grinding process. Optimization potential is wasted here because those who feed parts with a large oversize to the grinding process pay for the high surface quality with long process times and higher tool costs.
With our machines from the VLC GT Series, we regularly prove to our customers that there is another way to make the combination machining of components possible. In short, where turning is possible, turning is done and where grinding is necessary, grinding is done. The time savings with the combination of turning + grinding works much faster, as there is much less excess material left after turning. The optimally adaptable machining area offers a lot of freedom in process design; even components with non-round contours can be processed in this way.
By combining the hard turning and grinding processes faster cycle times, higher machining quality and lower tool costs will be achieved. These benefits become obvious when we look at the production of gear wheels. First, the shoulders are hard turned, and then the borehole and the cone are pre-turned. These processes leave a residual oversize of just a few micrometers on the gear wheel allowing for a significant reduction in the grinding process using corundum or CBN grinding wheels. The machining quality also benefits from the turning/grinding combination because if there is only a small amount of material to be ground after the turning process, the grinding wheel can be designed more specifically to achieve the final quality required. Allowing us to achieve finish values with a mean peak-to-valley height Rz of less than 1.6 micrometers using the VLC 200 GT.
The VLC series has a parts storage area for raw and finished parts, and working spindle that is automatically loaded/unloaded. This means minimum downtimes and high productivity.
Depending on the machining requirements, the machining area may feature one or two (internal) grinding spindles. Standard spindles are availablefor the configuration, which can cover a wide range of speeds and capacities..
CBN can be used to increase productivity. CBNgrinding wheels are conditioned with a rotating diamond dressing roller for the machining task.
Internal Grinding Spindle
Pick-Up Automation
External Grinding Spindle
+ REDUCED MACHINING TIME
The combination of hard pre-turning and grinding reduces machining time, enabling scroll-free surfaces to be achieved.
+ MINIMUM GRINDING WHEEL WEAR
The grinding wheel is subjected to less wear and is required to be dressed less frequently because the amount of material cut is minimized. This results in a significant increase in productivity.
+ FOR GRINDING WHEELS PERFECTED FOR THE PROCESS
As only a small amount of material needs to be removed with grinding, the grinding wheel can be designed specifically to achieve the desired final machining quality.
+ COMPLETE MACHINING IN A SINGLE CLAMPING OPERATION
Flat surfaces on the rear are difficult to machine by grinding due to their poor accessibility. This machining problem can be solved very simply by hard turning.
+ USE OF CBN GRINDING WHEELS (OPTIONAL)
CBN can also be used to increase productivity. CBN grinding wheels are optimally conditioned with a rotating diamond dressing roller for the machining task.
EMAG Tool Turret
By combining the EMAG tool turret with 12 tool positions (featuring either VDI, BMT or CDI interface) and a direct drive (torque motor), it is possible to achieve machining processes that are as fast as they are accurate.
Probe
The machine can be fitted with a probe for rapid quality control while the workpiece is clamped in. This probe is located between the machining area and pick-up area to ensure that it is protected from dirt.
The abbreviation “CVT” stands for “Continuously Variable Transmission”. This technology is frequently being used with hybrid drive systems and is an important component for the future of e-mobility.
At the same time as the electrification of the drivetrain, the CVT has also become established in passenger cars. This is mainly due to the high efficiency gearbox, whose infinite adjustment of the ratio without interrupting the traction ensures the perfect use of the energy supplied to it, lowering fuel consumption values.
For the production of the CVT disc, in addition to the tool turret, the VLC 200 GT has been fitted with an external grinding spindle with its capacity and the configuration of the grinding wheel customized to the workpiece.
The results of this combination of processes include lower tool costs and shorter cycle times.
The grinding wheel wears more slowly, and therefore has to be dressed less frequently. A long production cycle is made possible with an extensive tool turret with 12 tool positions. This means that sister tools can be used.
The combination of multiple machining processes in a single machine makes it possible to satisfy the rising requirements for the quality of the components and the desire for maximum machine flexibility. Various technologies such as turning, internal and external grinding, milling, reaming and honing can be combined as required on this series of machines.
The use of optimal processes and machining in a single clamping operation are the basis for the best workpiece quality. This means, for example, that workpiece contours can be pre-turned to ensure a constant oversize for the grinding process. This reduces the cycle time, particularly on workpieces with large or fluctuating oversizes.
+ STONE HONING
Stone honing as a finishing process to reduce peak-to-valley heights and increase the level of support.
E-BIKE
Shuttle automation for supply and removal of parts
External grinding spindle Probe
Rotating dressing roller
Pick-up working spindle
Internal grinding spindle
Turret equipped with 12 tool positions for hard turning tools
Siemens numerical control
+ BOREHOLE HONING
Honing the borehole using an expanding honing tool.
Combination machining of E-bike hollow shaft pre-turning and grinding the external and internal diameter Turning the flat surfaces.
+ BELT FINISHING
Belt finishing included in a VLC GT machine for very fine surface finishing
The VLC 350 GT from EMAG delivers high productivity and quality for grinding pump components.
They play an important role in the manufacture of pumps by contributing to the precision and efficiency of hydraulic systems. The radial piston pump is just one concrete application example used widely to transport lubricants in machine tools and automatic transmissions. The main components of the radial piston pump, such as the cam ring, are machined with high precision in the VLC 350 GT. The machining direction is the same as the later direction of rotation inside the pump, which minimizes noise development and enhances the pump’s efficiency.
In addition, the machine enables the processing of a large number of workpieces of different sizes. Another special feature is the wide spectrum of technologies. External cylindrical grinding, non-cylindrical grinding and face grinding are possible on the VLC 350 GT.
A probe outside the machining area, and therefore protected from dirt, is used for interim measurements in cycles or after a tool change.
The pick-up spindle takes care of loading and unloading workpieces from the shuttle or a peripheral belt.
The working area of the VLC 350 GT is individually adapted to the respective processing requirements. The machine can be equipped with up to three grinding spindles.
Out-of-round grinding of the internal profile, very good profile quality, excellent results for low-noise pump operation
These are hydraulic pumps and can generate high load pressure with little high pressure pulsation. They will also operate reliably over long periods of time. Another benefit of radial piston pumps is that they are robust and reliable even in difficult operating conditions. Furthermore, these pumps can handle a wide range of media, including highly viscous media, which makes them suitable for many different sectors, from food processing to heavy industry.
EMAG Salach GmbH
Austrasse 24
73084 Salach
Germany
Phone: +49 7162 17-0
E-mail: info@emag.com
EMAG Salach GmbH – Austria
Glaneckerweg 1
5400 Hallein
Austria
Phone: +43 6245 76023-0
E-mail: info@austria.emag.com
EMAG Salach GmbH – Sweden
Glasgatan 19B
73130 Köping
Sweden
Phone: +46 221 40305
E-mail: mkarlsson@emag.com
EMAG Salach GmbH – Hungary
Gerenda 10
1163 Budapest
Hungary
Phone: +36 30 9362-416
E-mail: lbujaki@emag.com
EMAG (China) Machinery Co., Ltd.
Sino-German Advanced Manufacturing Technology International Innovation park
Building 2, No. 101, Chen Men Jing Road
215400 Taicang
Jiangsu, China
Phone: +86 512 5357-4098
E-mail: info.china@emag.com
EMAG (Chongqing)
Intelligent Technology Co., Ltd.
24-7 Fangzheng Allee
Beibei Stadtbezirk
400700 Chongqing, China
Phone: +86 23 6824 8000
E-mail: info.china@emag.com
TAKAMAZ EMAG Ltd.
1-8 Asahigaoka Hakusan-City
Ishikawa Japan, 924-0004
Japan
Phone: +81 76 274-1409
E-mail: info@takamaz.emag.com
EMAG Salach GmbH – Czech Republic
Lávová 1628/8
104 00 Praha 10 – Uhříněves
Czech Republic
Phone: +420 731 476070
E-mail: mdelis@emag.com
EMAG Salach GmbH – Poland
Spółka z ograniczoną odpowiedzialnością
Oddział we Wrocławiu
ul. Krzycka 71A / 6
53-020 Wrocklaw
Poland
Phone. +48 728 389 989
E-mail: arak@emag.com
EMAG Salach GmbH – France
5 Avenue de l‘Europe
18150 La Guerche sur l‘Aubois
France
Phone: +33 02 48 7711-00
E-mail: info.france@emag.com
EMAG Salach GmbH – Spain
Pasaje Arrahona, n° 18
Polígono Industrial Santiga
08210 Barberà del Vallès (Barcelona)
Spain
Phone: +34 93 7195080
E-mail: info.spain@emag.com
EMAG Salach GmbH
Merkezi Almanya – Turkey
Istanbul Merkez Subesi
Sanayi Cad. No.: 44
Nish İstanbul Sitesi D Blok
D:155 34196 Yenibosna – Istanbul
Turkey
Phone: +90 532 694 54 44
E-mail: ckoc@emag.com
EMAG Milano S.r.l.
Via dei Mille 31
20098 San Giuliano Milanese (Mi)
Italy
Phone: +39 02 905942-1
E-mail: info.milano@emag.com
EMAG AMERICA
EMAG INDIA Pvt. Ltd.
Technology Centre No. 17/G/46-3, Industrial Suburb
2nd Stage, Yeshwantpur
Bengaluru – 560 022 India
Phone: +91 80 50050163
E-mail: info@india.emag.com
EMAG KOREA Ltd.
Rm204, Biz center, SKn Technopark
124 Sagimakgol-ro, Sangdaewon-dong
Jungwon-gu, Seongnam City
Gyeonggi-do, 462-721
South Korea
Phone: +82 31 776-4415
E-mail: info@korea.emag.com
EMAG Systems GmbH (Thailand)
Eastern Seaboard
848/14 M.3, Bowin, Sriracha
Chonburi 20230
Thailand
Phone: +66 (0) 38110485
E-mail: service.thailand@emag.com
EMAG L.L.C. USA
38800 Grand River Avenue
Farmington Hills, MI 48335
USA
Phone: +1 248 477-7440
E-mail: info@usa.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, Querétaro
Mexico
Phone: +52 442 291 1552
E-mail: info@mexico.emag.com
EMAG DO BRASIL
Edifício Neo Corporate Offices, CJ 1503
Rua Enxovia, 472
04711-030 São Paulo SP
Brazil
Phone: +55 11 38370145
E-mail: info@brasil.emag.com