At Gear Expo 2017, October 24-26. at Greater Columbus Convention Center in Columbus, Ohio, EMAG USA will feature manufacturing systems for precision metal components with a special focus on its efficient and diverse solutions for gear manufacturing.
The modular VL Series for chucked components will be on display, with its VL 4 machine, for visitors to experience the successful EMAG modular inverted vertical lathe design. With the goal to develop a system of modular machines geared for use in the manufacturing of medium and large batch runs, EMAG offers flexible solutions on a standard machining platform. For example, the process of single spline hobbing can be performed on a VT vertical lathe for shafts. With the capability of offering gear cutting on a standard machine, EMAG modular machines offer flexibility over specialized and custom-hobbing machines. Machining is performed on four axes at a maximum speed of 6,000 rpm. The process employs two turrets with 12 tool stations each, equipped with turning tools or driven tools. One common feature of the VL and VT machine sizes is the shared modular design. Their small footprint reduces floor space costs and increases flexibility in floor layout options. Every VL and VT machine features an integrated automation system for transporting workpieces. When combined with the self-loading pick-up spindles, this automation concept ensures short cycle times and high productivity. To accommodate machine operators, all the service units are easily within reach, with the various units (electrics, hydraulics, cooling system, cooling lubricant and central lubrication system) accessible at any time so the machines can be maintained with ease. While the standard lathes are commonly used for gear blanks, a wide range of technologies can be incorporated into the machines, including turning, grinding, hobbing, chamfering, induction hardening, and laser welding.
The technologies in the EMAG Group cover the entire spectrum of metalworking — including non-traditional processes. Laser welding is essential in the light weighting of automotive components while electro-chemical machining (ECM) is a broaching and deburring option. For more information on ECM Broaching, EMAG ECM experts will be giving a presentation on the topic in the Solutions Center at the show. In addition to the VL 4, EMAG will have an eldec induction hardening system with a modular induction (MIND) machine at the show. Featuring Simultaneous Dual Frequency (SDF) technology where two different frequencies are applied to the workpiece, MIND machines can apply mid-frequencies to penetrate deeper and heat the root of the gear tooth simultaneous to high frequencies to accurately heat the tip of the tooth. Eldec hardening systems compliment the workpieces machined by EMAG lathes to create efficient, complete production lines. The flexible machine concepts and complete systems from EMAG offer modular and customized solutions for the production of workpieces in nearly every industry. EMAG looks forward to welcoming visitors to booth 1107.