Vertical turning center VL 4 for chucked components up to 200 mm in diameter
The VL 4 vertical turning center is able to machine workpieces having a maximum diameter of up to 200 mm. The VL 4 is one of EMAG's modular turning centers that stand out by their very compact design. Like all vertical turning centers in this series, the VL 4 also features an integrated pick-up automation system.
With the VLC 350 GT turning/grinding machine from EMAG, a variety of hard machining processes are performed one after the other on chucked components up to 350 mm (14 in) in diameter, in a single clamping operation.
The VT 4 and VT 200 (the VT 200 has an identical structure to the VT 4 but with a Siemens control system) are designed for the complete machining of shaft components with a maximum length of 630 mm (25 in) and diameter of 200 mm (8 in). Machining is performed with two twelve position tool turrets (one slot in each is occupied by the workpiece gripper), making it possible to machine pieces on four axes, from two sides simultaneously.
VL 2 ? Vertical Pick-Up Turning Machine for Chucked Components up to 100 mm in Diameter
A stable machine structure, dynamic axes and ease of operation - these are the outstanding features of the VL series vertical turning machines. Based on a completely new modular machine concept, VL 2 vertical lathes make it possible to utilize various production technologies for soft and hard machining with integrated automation and a pick-up spindle, all while providing the best value for the investment.
EDNA IOT-READY EX-WORKS: Get started with data-optimized production with VL series
Using data analysis, unnecessary downtimes ? due to component wear or, in the worst case, due to the failure of a machine ? can be reduced or even avoided entirely. Productivity increases of over 10% are the rule here. To make entering the world of data-optimized production as easy as possible for our customers, all the machines of the VL Series now come standard in an IoT-ready state. This means that data analysis on the machines can be started virtually immediately.
EMAG has extended the product range of the extremely successful VL series in the form of the VL 3 DUO, a twin-spindle machine solution for efficient manufacturing of chucked parts with a maximum diameter of 150 mm.
The VL 3 Duo design incorporates technological developments from EMAG over the last few years including pick-up and TrackMotion automation systems and modular design. These advancements are paired to create a highly productive manufacturing system that delivers maximum productivity with the smallest possible footprint.
Vertical turning and grinding ? a combination that has everything. The VLC 200 GT combines the benefits of vertical hard turning with those of grinding ? on a single machine and in a single clamping operation.
The VLC 200 GT is specially designed for precise, process-reliable and cost-effective manufacturing in medium- and large-scale production. Typical workpieces machined on the VLC 200 GT include gear wheels, sprocket wheels, sliding sleeves, parts for CVT gears, bearing rings and piston rings.
VT 2 - The turning machine for vertical 4-axis shaft machining
Where shaft machining involves large numbers of workpieces, the first choice must be the VT series of turning machines. In the machining of shafts on turning machines the focus is on the speed of the process, whereby both loading / unloading and the machining cycle need to be very fast. This optimal requirement is fulfilled with the VT 2 turning machines.
Four axes, short travels, powerful mainspindle ? these are the strengths of the VT 2 turning machines. The full impact can be best felt where the component batches are large. Of decisive importance in the use of these turning machines is the ?two-sided? machining process, which massively reduces the machining time on the VT 2 turning machine.
The strength of the VTC 100 Vertical Turning Machine lies in the production of large quantities of shafts with diameters up to 400 mm. Full integration into the EMAG machine concept including automatic loading and unloading of the workpieces offers a manufacturing system that is characterized by short travel distances and fast loading of via the turret. This is complemented by a powerful main spindle (34 kW, 144 Nm, 6000 rpm).
VM 9 Vertical Turning Center for the Manufacture of Large Components
With the new VM 9 vertical turning center, EMAG has introduced a platform that covers a broad spectrum of applications thanks to the combined turning, milling and drilling technologies and intelligent machine design. The highly accessible machining area and workpiece spindle fitted at the bottom ensure short tooling times and maximum flexibility in the production of large components.
W 11 CNC External-Internal Face Cylindrical Grinding Machine
When a high-end CNC machine is too much and a conventional machine is too little, the solution is: EMAG WEISS W 11 CNC CYLINDRICAL GRINDING MACHINE.
With the W 11 CNC, you can produce workpieces with a maximum diameter of 350 mm (14 in) and a length of 2,000 mm (79 in).
The W 11 CNC cylindrical grinding machine is perfect for one-offs and prototype production. This cylindrical grinding machine is also used for small batch production with a few diameters, for match grinding and sample production in the field of training and maintenance.
The VLC 450 DG is a special machine for the high-precision grinding of hard-coated brake discs. This machine was developed with a focus on rigidity and durability to meet the high demands of batch production. The vertical design ensures optimum removal of the hard material particles and offers excellent accessibility for maintenance work. This makes the VLC 450 DG a reliable solution for brake disc production that meets the highest productivity levels and workpiece quality requirements.
The W 11 EVO from EMAG Weiss is a manual cylindrical grinding machine that combines traditional know-how with modern technology. It has been specially developed for demanding tasks in tool and mold making, maintenance staff or training facilities. The W 11 EVO combines manual precision with the possibility of using servo-electric axes for automated processes, making it a flexible and high-quality solution for specialized grinding tasks.
VTC 100 GT ? Small, compact shaft manufacturing cell
The VTC 100 GT turning and grinding machine ensures fast cycles for hard turning and grinding. The tool turret completes all turning operations, while the grinding takes place at a second station. Thus, the VTC 100 GT multi-functional machine is the perfect production tool for the complete machining of cylindrical bearing seats or shoulders and grooves, for example. Machined in a single clamping, true running errors resulting from separate clamping operations are reduced.
Perfect Combination of Power Skiving and Turning
Fast, precise, and easy to operate: power skiving has been turned into a highly efficient process for the production of internal and external gear teeth by the VSC 400 PS machine.
Responsible for this is a high-performance tool concept. The VSC 400 PS can accommodate up to four different power skiving tools on two spindles, plus up to six turning tools. This enables various combination processes with a single clamping operation:
1st variant: Roughing (for example with an indexable insert tool) and finishing (for example with a carbide tool) take place in rapid alternation.
2nd variant: Up to four different types of external and internal gear teeth are produced with four tools.
3rd variant: The combination of pre-turning and power skiving ensures speed and precision in concentricity.
The G 160 gear generating grinding machine presents a unique design to optimize the dynamic stiffness compared to current standard machine architectures.
The G 160 gear generating grinding machine splits the X-axis of current machines into two linear slides (X1, X2), each of which carries one workpiece spindle.
So both work-spindles are under full position control anytime. Being driven by high dynamic 30 m/s linear motors, changing spindles comes down under 2 seconds including simultaneous repositioning of the grinding wheel. The machine architecture with only three axes instead of 4 axes concept of current machines, is a breakthrough.
The HLC 150 H is a gear hobbing and worm milling machine with outstanding versatility and flexibility. This high-performance gear machining center caters to a very wide workpiece range: From gears and pinions for gearboxes over armature shafts and worms up to transmission shafts with total length of up to 500 mm (20 in).
Horizontal Hobbing Machine with Integrated Chamfering Unit for Maximum Productivity
The new HLC 150 H stands out for its numerous innovations and covers a unique spectrum of production applications.
Steering gears or shafts, straight, angled, or worm gearing the HLC 150 H puts the full expertise of EMAG KOEPFER at the users disposal. This unique machine is complemented by a device for the chamfering and deburring of components during loading and unloading without interrupting operation. As a result, it offers perfect gear-cutting, short cycle times, and minimum cost.
With the PI modular machine platform, EMAG?s successful concept, i.e. same basic structure combined with customized technology, now also makes inroads at EMAG ECM. This offers you maximum flexibility for your machining projects in the area of electrochemical machining (ECM/PECM).
The right module for each application in electrochemical machining.
Electrochemical machining (ECM or PECM) can be used to machine a great number of different workpieces. Which technology comes to be used depends on the requirements of the workpiece. ECM can be implemented for deburring, drilling, broaching or even for gear cutting. If you want to achieve a high level of reproduction accuracy, then PECM is the right choice.
EMAG ECM already offers highly specialized machine solutions for both technologies, which are implemented for a wide variety of industries throughout the world. Above all, ECM and PECM are implemented wherever demanding materials (e.g. very hard) are to be machined or if material removal technologies reach their limits or simply are too expensive, e.g. if a burr and chip-free component can only be achieved through elaborate finishing.
The economical solution for the complex machining of turbine blades
Electro-chemical Machining (ECM) is the generic term used to describe various process variants.
The ECM process manufactures workpieces through the electrolytic dissolution of metal. The process is used in the aerospace, automotive, medical, micro-system and energy industries. Almost all metals, even exotic materials such as nickel-based and titanium alloys or tempered materials can be easily machined using this process.
The drawbacks of conventional metalworking, such as tool wear, mechanical stress, micro-cracking from heat input, oxidation coatings or subsequent deburring work do not occur with this non-contact machining process. ECM features material removal without any inherent stresses, soft transitions and smooth finishes.
The EMAG ELC 6 is a production laser welding system for maximum output and is ideal for classic powertrain components with round welds. The machine is based on a rotary indexing system with a machining station and a loading and unloading station.
EMAG ELC Laser Welding Systems are compact, laser-equipped machine tools that can ? on the basis of standardized platforms and machine assemblies ? be configured to match component-, customer- and project-specific manufacturing systems.
EMAG ELC Laser Welding Systems have been developed and optimized - uncompromisingly ? for the production laser welding of high-quality components.
ELC 250 DUO – the multifunctional laser welding machine
The ELC 250 DUO also works on the pick-up principle: the spindle loads itself and positions the workpiece where the welding optic requires or takes it to other processing modules.
The ELC 250 DUO features two independent machining stations that share a single laser beam source; i.e. the laser beam is switched between stations. This increases productivity (cycle tome-concurrent component loading and unloading) and allows for the parallel machining of different workpieces or the inclusion of complex downstream machining operations (e.g. laser cleaning / joining / welding / brushing / checking). The result is optimal technological flexibility.
The principle of a stationary optic allows for the integration of all laser technologies: the ELC 250 DUO can be equipped with either CO2 lasers or with solid-state lasers (fiber, disc). A number of different machining optics are available to suit a variety of requirements.
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