Machining of large cast and forged parts
... is part of the Modular Standard family from EMAG and is characterized by a bottom-mounted spindle. This machine is designed for larger workpieces with a diameter of up to 450 mm, a weight of up to 300 kg and a height of up to 300 mm. The machine has a compact footprint of 1.80 m wide and approx. 5 m long including chip conveyor, which saves space in the production hall compared to conventional horizontal machines.
The VM 9 from EMAG has been specially developed for the machining of large castings and forgings typically used in trucks, construction machinery, agricultural machinery and general engineering.
The machine is suitable for both turning and complete-machining of these components. A particular focus is on the machining of brake discs for trucks and cars, which particularly benefit from the lower spindle arrangement due to their size and the precision required.
The VM 9 is also suitable for machining workpieces where the use of the lower spindle makes sense due to the size and weight of the workpieces. The machine is also suitable for small to medium batches as well as for single part production and has a special turret for green turning brake discs including the braking surface.
Automation solutions, such as robotic automation, are available for the VM 9 and are particularly beneficial for handling heavy workpieces that exceed the capacities of conventional pick-up machines. The machine is designed to overcome the challenges of machining cast iron dust, particularly when dry turning brake discs, by incorporating special guards and extraction systems to ensure performance and cleanliness of the work area.
LIFT-OFF STEEL HOLDER FOR finish-turning the braking surface
» Main spindle with direct drive and C-axis
» Turret with 9 + 1 tool positions (1 for lift-off tool holder)
» Minimal footprint
» Flexible workpiece loading concept with side loading hatch for robot automation
» Optimum chip fall for demanding turning operations (dry casting machining)
By operator via automatic or manual loading door/front side
The automation capabilities of the VM 9 include various options that can be used depending on the batches and production requirements.
With crane or lifting device via automatic front door in L-shape
For single parts or small series of up to 20 workpieces. The machine is ergonomically designed so that the operator can easily reach the spindle and load the workpieces without physical eff ort. The operating door can be opened manually or automatically, which is the easiest form of loading.
The with gantry loader is suitable for medium batches of up to 1,000 components and especially when linking-up several machines. The machine is prepared for the connection of a loading gantry, whereby part of the machine roof is opened to facilitate access from above. This enables the link-up of machines with a gantry to automate the machining of workpieces in multiple operations.
Batches: 1 – 20
Batches: 1 – 1,000
With the robot via the loading fl ap on the left-hand side
The use of a robot makes sense for larger quantities. The machine has an automated loading door on the side that provides access for the robot. This option enables highly automated feeding and removal of the workpieces and sets virtually no limits in terms of quantities.
Batches: 1 – 75,000
» Space requirement in the factory = 3 x 46 m² (3 x flex line)
» Less personnel required: 50%
» High availability thanks to fast machine setter without downtime
» Loading: automatic AND/OR manual
The basic body of the VM 9 is cast from mineralite, which off ers excellent thermal properties and vibration damping. This leads to a better surface finish of the workpieces and longer tool life due to less wear.
Machine base body made of MINERALIT®
12-station turret BMT65/VDI40
Main spindle: The machine is equipped with a powerful main spindle from EMAG. It has a drive power of 38 kW, is equipped with permanently grease-lubricated bearings in a tandem O arrangement for high stability and delivers up to 500 Nm of torque. The maximum spindle speed is 3000 motor speeds per minute.
Ergonomics and accessibility: The spindle height is designed so that the operator can insert the workpieces ergonomically by hand, which is particularly advantageous for manual loading.
Integrated measuring probe: The VM 9 has an optional measuring probe integrated in the turret. This is a huge advantage, as it supports process quality and enables precision measurements directly in the machine.
Revolver variants: There are two turret variants - one with a classic drive and one with a direct drive, which off ers higher performance values in terms of torque and motor speeds. The direct drive turret is recommended for more complex machining tasks.
Tool stations: The turret has 12 stations with BMT65 or VDI 40 interface.
0.3 SEC. Revolver swivel time
Feed
SPINDLE
Spindle flange
