Innovative Processing Speeds Reduce Idle Times
How the production technology changes under these conditions is demonstrated by an innovative new machine from EMAG: the VLC 250 PDS. It was specially developed  at the request of a customer who wanted to grind their ball screw nuts. Of course, the machine can also be succesfully used for many other two-stage grinding processes. Its innovative processing speeds – achieved  with two pick-up spindles on the same axis – ensure extremely short idle times. While one pick-up spindle removes a component from its particular infeed system at one side and conveys it to the measuring probe, the second pick-up spindle is already in the machining area, conveying the ball screw nut to the two grinding spindles (where the two-stage grinding process is carried out).

Correct positioning is imperative
What‘s the advantage of this approach? The answer relates to the correct positioning of the workpiece in the machine: before the grinding process can begin, the component’s inner contour has to be aligned to ensure the grinding spindle can be positioned at the end of the thread – a pretty time consuming process. In order to achieve this, EMAG relies on its perfectly timed system, while the measuring or positioning of one workpiece is completed simultanously with the machining of another. This reduces unproductive idle times.

Keeping an Eye on new Components
“Pendulum grinding“ is what the engineers call this revolutionary and high-performance approach that relies on the machine details.. For example, the two pick-up spindles are mounted on particularly sturdy compound slides; while the powerful linear motor in X-axis generates high acceleration values. And the necessary workpiece quality is achieved by the machining in one set-up – a standard benefit of EMAG machines. It is obvious that this design could, in the future, be used for many other applications that call for a two-stage grinding process. Of course, many production processes would benefit from the innovative processing times one can achieve with two pick-up spindles. Over the next few years EMAG intends to promote the advantages in the market vigoursly.

In the automotive industry, one trend has been consistent for years: Passenger vehicle transmissions are becoming smaller and lighter, although the number of speeds—and of toothed gear components—continue to increase. How does the entire assembly not become heavier?. The answer becomes obvious by taking a closer look at the individual components. A gearwheel, for example, consists of two components that are joined by laser welding. This allows the design engineers to work without screws—allowing the component to become lighter.

Integrating the into the production system

The benefits listed above explain why laser welding has become a core process in transmission manufacturing. However, this method cannot easily be integrated into a complete production line: because the actual laser welding process is preceded and followed by many other processes. Depending on the component, these may include checking, washing, joining of components before laser welding, a brushing process and a final ultrasonic inspection of the welding seam.

EMAG developing multi-stage production solutions

“Implementing comprehensive production lines that integrate laser welding into the overall sequence—is the special expertise of EMAG Automation”, says Dr. Andreas Mootz, managing director of EMAG Automation. “We are very familiar with the production sequence for central transmission components. Therefore, we do not just design another laser welding machine. With our multi-stage production solutions, we focus on creating a perfect process chain that operatesquickly, and very safely.”

Every detail of these systems is perfectly tailored to the component by our specialists based in Heubach near Schwäbisch Gmünd, Germany. Inspection methods, as an example: EMAG Automation has developed its own ultrasonic inspection method. “The trend goes toward zero-defect production that ensures the quality of every single welding seam. We can guarantee it with this technology”, says Dr. Mootz.

ELC series—a success story in transmission manufacturing

Of course, the laser welding machine itself is perfectly configured as well. It is always a customized solution, based on the ELC series machines—each model being ideally suited for different types of components. For example, the ELC 160 HP machine is a special solution for gearwheels. On the other hand, the ELC 160 model provides an all-round solution for many automatic transmission and dual clutch components. Another major success factor is the cooperation between EMAG Automation and EMAG Maschinenfabrik in Salach. By combining their resources, they can implement the complete production sequence for transmission components—from welding to turning and grinding. “In this way, production planning has become so much easier. This is a huge benefit that is continually increasing its market recognition “, concludes Dr. Mootz.

Gears keep the world moving. They are found absolutely everywhere, in many different shapes and made from an extremely wide range of materials. From the tiniest, most delicate gears used by watchmakers, to gears with a diameter of 16 meters used in mines and the cement industry, where they drive gigantic mills and rotary kilns. Big or small, they all have one thing in common: they must satisfy the most demanding requirements.

KOEPFER, a company with years of success in the gear cutting field, has demonstrated its capabilities in a multitude of projects for a broad clientele. Satisfying the most demanding requirements is second nature for the company’s gear cutting experts, who meet such requirements head on with the necessary expertise and first-rate technology.
Technology like that used in the new modular hobbing machine VL 4 H, which is the experts’ answer to the demands of high-volume manufacturing.

VL 4 H – a Modular Machine from EMAG
EMAG’s modular machines are part of a successful machine series that combines the different technologies of the EMAG Group on a standardized machine base. Whether for turning, grinding, induction hardening, or gear cutting, the proven EMAG pick-up principle ensures highly automated, efficient production. The pick-up automation system integrated into each modular machine features a parts storage unit for blanks and finished parts, from which the machine is automatically loaded. This system allows for very short chip-to-chip times of only a few seconds. The vertical construction of the machine not only guarantees an ideal chip flow, but also prevents the formation of chip clusters, thus contributing to a consistently high quality of production.
The compact vertical design of the machines makes them very attractive, both as single units, and as part of an interlinked manufacturing solution. The interlinking option is easy to implement due to the consistent transfer height between the automation systems of individual machines. In addition, the separate energy container allows the use of the new EMAG TrackMotion automation system specially developed for modular machines. The automation, system located directly behind the machining area, transports the parts and also operates as a flip-over unit, which increases the flexibility of the entire system.

Gear Hobbing and Chamfering on a Single Machine
The vertical VL 4 H hobbing machine can be configured for a wide range of applications. The high-performance drives used in the working spindle and the hob enable high speeds and torques, ensuring fast, precise and cost-optimized gear production. The machine allows the dry gear hobbing of workpieces up to 200 mm in diameter and module 4. The optional measuring system for part alignment can be expanded by adding a sensor system for positioning. It is installed outside the machining area where it is protected from chips and dirt; it can also be extended and retracted as required. This not only allows adjustments to be made to the machining operations at any time, it also permits seamless documentation for production quality assurance.

The machining area of the VL 4 H is easily accessible through the large front door, allowing rapid set up times and creating an ergonomic work environment for the operator. The combination of powerful drives, a working spindle that can be controlled with absolute precision, tool clamping, and the generously dimensioned machining area allows various different gear cutting methods to be used on the machine. For instance, the CHAMFER CUT method can be used to chamfer the workpieces directly after hobbing, with a single clamping operation. To do so, the CHAMFER CUT tool is mounted on the hob arbor of the cutter in addition to the hob. The CHAMFER CUT method, developed by FETTE, is ideal for precise and low-cost chamfering processes. “As this method does not produce any secondary burr and does not warp the material, it is especially usefulfor gear teeth that are honed after hardening,” said Jörg Lohmann, head of sales at EMAG KOEPFER. To be effective however, the workpiece does have to have a suitable shape, however. “We have successfully tested this machining combination in the manufacture of gears. The wheel-shaped workpieces have hardly any interfering contours, so that chamfering with CHAMFER-CUT is possible. The machining combination of hobbing and chamfering in a single clamping operation, on one machine is a very cost-effective solution for the user, as two manufacturing processes can be carried out at the same time with just one machine, and the workpiece handling between the processing steps is also eliminated. That lets you reduce your floor to floor times and get workpieces to the next production step faster,” Lohmann explained.

VL 4 H – High Degree of Freedom for the User
The new VL 4 H from EMAG KOEPFER offers users a multitude of possibilities. As shown in the example, it can be used as a standalone machine for gear cutting, or for combined hobbing/chamfering. This machine can also be part of a production line, which is easy to do thanks to the advantages of EMAG’s modular machines. In all cases, the user benefits from the many possibilities that the machine offers. In conclusion Lohmann had this to say: “At KOEPFER, we place a tremendous amount ofvalue on giving our customers the optimal advice. With the VL 4 H we have now added another valuable module to our standard modular machine series, which allows us to offer our customers the best possible manufacturing solution for their application, all the way from standalone machines to highly automated manufacturing systems for large-scale production.”

Composite camshafts are increasing in importance, as they decrease in weight, providing more opportunities for automotive manufacturers. The heat-shrink processachieves new levels of flexibility thanks to the new SFC 600 heat-shrink machine from EMAG.

Camshaft variants are joined via heat-shrink in quick succession

The heat-shrink assembly of camshafts provides the automotive industry with many advantages. For one, the design is based on a tube, howevers it’smuch lighter, compared to the traditional monoblock design. Another plus is that manufacturers can use the ideal material for each individual camshaft component. For instance, the cams are sintered, whereas subordinate components – such as plugs and end pieces – are made of more favorable materials. This approach reduces costs and makes production planning and implementation of the camshaft easier.

New Opportunities for Heat-Shrink Technology

For over 20 years EMAG Automation has developed its patented heat-shrink technology. The cam is heated inductively, where it then expands, and is fitted onto the shaft with no force involved. The whole process is carried out at a temperature level generated to suit the specific material and component geometry. The heat-shrink process starts when the component is subsequently quenched. The result is an air-tight shrink-fit. With their new SFC 600 shrink-fit machine, the creators of this technology open up new opportunities, where the shrink-fitting of camshafts up to 600 mm length gets even faster and noticeably more flexible.

Rapid Workpiece

At the center of the solution are particularly fast and precise NC axes with linear motor technology. With this technology, it is possible to control the whole production process with an NC program – which is necessary for flexibility. Depending on the camshaft model, it is sometime sufficient to simply adjust the NC program.The whole user interface is made to suit the programming of the machine tool. All data is stored in the control system. “The changeover from one camshaft production to another takes less than ten minutes”, explains Mr. Wolfgang Bohn, Application Engineer at EMAG Automation. The system is particularly effective where retooling is a frequent requirement, as most tools in the SFC 600 do not have to be retooled.

60 Second Assembly

The cycle times for the actual shrink-fit process are also very short. The gantry loader picks up two shaft components simultaneously and takes them to the two inductors to be heated. An NC-controlled twin-gripper then takes over the two components and pushes them onto the shaft, as described. Making it possible to completely assemble a standard 4-cylinder camshaft in about 60 seconds. “The SFC 600 makes the process faster, more flexible and easier to control”, summarizes Mr. Bohn. “We’re sure that our combination of heat-shrinking and NC-based drives will chave a major impact in camshaft production.”

When the time comes to finish such hardened workpieces as shafts, a variety of processes can be used. Hard turning and scroll-free turning, for instance, are two options that can indeed be done quickly. But they can only be used if workpiece qualities and geometry are just right. Otherwise, grinding becomes the process of choice. This creates a difficult decision: Just which technology or which machine should I select as a manufacturing planner?

Several processes on one machine

The optimal solution is, of course, the one that requires you to make no decision at all because you can draw on all technologies at the very same time. This is exactly the concept that EMAG is applying with the VTC 100 GT, a shaft machine on which all end production technologies can be used. As a result, the user has maximum flexibility and can retool the machine with the technology that best suits the component to be produced.

Perfect accessibility and integrated automation

The user also profits from another feature. The machine provides optimal accessibility despite its small footprint. As a result, nothing can stand in the way of rapid retooling. An integrated turret with 11 tool stations ensures rapid machining. This disc-type turret is also equipped with a tool gripper that can be used to automatically load the machine from the integrated conveyor belt.
In addition to the disc-type turret, the machine comes with a grinding wheel. As a result, a grinding operation can be conducted immediately after the turning process – in the same set-up – a bonus feature that not only reduces processing time, but also eliminates reclamping errors.

Flexibility pays off

There is no doubt about it. Users of the VTC 100 GT hold all the aces. Depending on the workpiece involved, they can select the best-possible end-machining process, an option that pays off in terms of machining time, workpiece quality and energy consumption. The integrated automation and the array of machining technology options in a single set-up also help lower costs because workpiece quality rises as the machining time falls – a real win-win situation for users.

The future is one of driverless cars which will drastically change traffic and the experience of driving. This is one finding of a recent study by McKinsey & Company entitled “Autonomous Driving – 10 ways in which autonomous vehicles could reshape our lives.” McKinsey predicts various changes for manufacturers, including reduced development times, new competitors from high-tech and IT industries and the development of completely new business areas. Autonomous driving places very high demands on sensors, electronics and especially on the electromechanical components of current and future steering systems without which driverless cars would not be possible. Steering pinions are one of the standard components of these steering systems and are parts which must not only be manufactured in large volumes but also in top quality and at the lowest possible cost.

The specialists at KOEPFER, a subsidiary of the EMAG Group, are very familiar with electromechanical as well as traditional hydraulic steering systems. Jörg Lohmann, Sales Manager at KOEPFER, is in a perfect position to report the following: “Our customers’ goal is reduce the amount of production outsourced due to various processes and to ultimately reduce overall cycle times. One solution is to offer complete production lines at one site for strategic components. This also affords one the chance to review current setups and, in some cases, completely remove steps no longer necessary from the manufacturing process, aiming, of course, to sink production costs.” EMAG KOEPFER offers such modular vertical solutions alongside its highly efficient horizontal hobbing machines known for maintaining quality despite high productivity. The solution provided depends, of course, on the manufacturing strategy of the customer.

Large-scale steering pinion production

The K 160 features a high-speed portal loader with double rotary gripper to reduce the loading time to a few seconds. This challenge should not be underestimated when machining steering pinions, since the milling process often has to be carried out at a defined angle to existing slots, drilling templates or contours. A specially developed orientation device is the solution in this case. Lohmann continues: “Since the actual machining of the steering pinion only takes a few seconds, the idle times resulting from the loading and orientation processes can be reduced to an absolute minimum to maximize the machine’s efficiency. The high-speed loading solution we have developed enables production machining times of under 20 seconds to be achieved, which represents an enormous increase in productivity for an output volume of 100,000 to several million units.”

Complete production at a glance

EMAG also developed a steering pinion manufacturing system based the company’s modular machine portfolio. EMAG uses the VTC 100-4 vertical pick-up turning machine, the customized version of the well-known VT 2-4 for turning the raw parts. The gear hobbing technology on the VLC 200 H vertical gear hobber then produces the toothing. The VLC 100 IH vertical hardening machine is then used for the inductive hardening process and the VTC 100 GT vertical turning and grinding center delivers the perfect finish and perfect surfaces in the final stage of the process. Should any additional finishing be necessary to the tooth profile due to quench distortion, the VLC 200 H, with skiving capabilities, is suited for the task.

Linking made easy – modular machines from EMAG

There are good reasons in favor of using EMAG’s modular machines in production lines, as the standard basic design delivers many major benefits.  Each machine has a base made of Mineralit® polymer concrete, which has excellent damping properties to reduce vibration and improve component quality. EMAG’s typical design includes an automation system and parts storage facility configured to suit specific requirements, both of which are just as integral to the modular machine concept as the pick-up automation system, in other words the automatic loading and unloading from this parts storage facility. The entire process takes place in just a few seconds to maximize the machines’ output. As the storage component is at exactly the same height on all the modular machines, transporting the workpieces between them is greatly simplified. Comparatively simple automation components, such as conveyor belts, pick-and-place units and changers make it possible to link the modular machines as required. These simple solutions not only guarantee low costs, but also require very little space – an entire EMAG production line for steering pinions can be installed on a surface area 15 percent smaller than other standard solutions. The lowered maintenance requirements compared to solutions with portal loaders or robots should also not be underestimated. The vertical design of the machines allows the spindle, slide and parts transport system to be arranged in a very compact form, which also helps to reduce the manufacturing system’s footprint.

The machines in detail

The VTC 100-4 four axis vertical turning machine for shafts clamps raw parts between the central main spindle and the tailstock beneath it. There are two turrets with twelve tool positions available for loading and machining processes with one of the turrets’ tool positions housing a workpiece gripper to transport the shaft in and out of the vertical turning machine. The turrets can be equipped with either turning or driven tools for machining operations. There are endless transport belts on both sides of the machining area.

Next a pick-up spindle is used to load the VLC 200 H vertical gear hobbing machine. After the workpiece has been transported into the machining area, KOEPFER’s gear hobbing technology takes charge. The high-performance drive units, which deliver high torques and speeds to the spindle and hob cutter, ensure that toothing up to module 4 can be produced quickly and with high precision. The new VLC 100 IH is responsible for the hardening process. This combines the basic design of the modular machines with the induction hardening technology of eldec, another subsidiary of the EMAG Group. The finish machining of the steering pinions takes place on the VTC 100 GT turning and grinding center. This machine has a disk-type turret with eleven tool positions (the twelfth tool position houses a loading gripper) and a grinding wheel. The benefit of this machine becomes quite clear as the combination of turning operations such as hard or scroll-free turning together with  grinding technology ensures a much faster machining process compared to classic final grinding, while still delivering the same quality. The workpiece spindle has a torque of 70 Nm and a drive rating of 17 kW to ensure that the machine has all the necessary power to effectively complete difficult machining processes.

Regardless of how the automobile market develops, EMAG continues to prove that it is perfectly prepared to face future challenges with its products and production solutions. The wide range of technologies available in the EMAG Group allow the company to react flexibly to market developments and also develop unequaled, all-in solutions.

At the China International Machine Tool show (CIMT) that takes place from the 20th to the 25th of April at the New China International Exhibition Centre (NCIEC) in Beijing, the EMAG Group will – on stand W1-324 in Hall W1 – be presenting exciting new developments in the machining sector. For example, the exhibited machines of the VL series – with integrated pick-up automation and easy to link up to other machines – make ideal manufacturing systems for chucked components, optimally suited for the use in production lines for medium and large component batches.

The VL series consists of vertical pick-up turning machines for the medium and large batch manufacture of chucked components with a max diameter of 400 mm and forms part of the highly successful modular machine concept that EMAG first introduced in 2013.

The special features of the modular machine concept include a uniform basic machine construction that always includes integrated pick-up automation. This distinctive characteristic of the modular machine, where the pick-up spindle loads and unloads the workpieces from an also integrated parts conveyor, forms the basis for the outstanding performance of the VL series.

The different types of automation
As indicated by the expression „modular“, the machines of the VL series can be customised to suit a variety of manufacturing scenarios. Besides the machining technologies that can be applied, this also refers to the automation systems used for the component transport. At the CIMT in Beijing EMAG will present two VL 2 machines interlinked by means of a turnover unit. This allows for chucked components to be complete-machined in just two setups. After the first VL 2 has pre-machined the component in a first setup, the workpiece is turned and transported to the second VL 2, where it is finish-machined in a second setup.

Integration into production lines
When the EMAG engineers developed their type of modular machines, including those of the VL series, their focus was firmly on the high-productivity manufacture of medium and large component batches. It should therefore come as no surprise that the machines of the VL series are all fully prepared for the link-up of a number of them, to be integrated into production lines. The small footprint of these vertical machines and the unchanging transfer height of the workpieces make planning the automation system components child’s play – compared to horizontal machines.

Corner stones of the manufacturing solution

• Low-manpower production
• Turnover and transport units handle the components between machines
• Economic raw-part supply in pallet cages at the start of the production line
• U-automation provides large component buffer

The advantages of the VL 2

• An uncomplicated automation concept ensures top machine availability
• Integrated automation, automatic workpiece changes
• Short travels for machining and loading, resulting in short cycle times
• The machine base in polymer concrete MINERALIT® provides a high degree of stability and has outstanding
• vibration damping qualities
• Ideal chip flow conditions
• Small footprint
• Exceptionally easy access to machining area and service units
• Uncomplicated tool changes
• Integrated component measuring (optional)
• Optional Y-axis

The EMAG products cover the entire spectrum of machining processes in the metal working industry. At IMTEX 2015, the company has exhibited its head-turning product VL 4, one of the model in the VL series turning machines.

Components are becoming smaller and smaller without sacrificing sharp precision whether it is the car engines, energy management or general mechanical engineering. The VL 4 turning machines provide an efficient solution to innumerable production challenge.

With its variety of technology centers EMAG has become an important partner in the realization of complete process streams for the manufacture of transmission, engine and chassis components.

The design of the new VL 4 turning machine allows various flexible production technologies to be used for both soft and hard machining.

The Benefits

• Machining of chucked parts equals standard machine concept
• Small footprint (chaku-chaku or close linear arrangement) equals reduced floor space costs, more possibilities for the machine layout
• Possibility of simple interlinking via central feeding and discharge belts and pick-and-place unit / changer equals flexibility as regards to future developments, lower automation costs, and shorter tooling times Integrated automation
• Short transport distances
• Lower maintenance costs
• Ease of operation and quicker machine set-up
• High energy efficiency equals reduction in energy costs
• Ideal for medium and large scale production

Technical Data VL4

• Chuck diameter: 260 mm 10 inch
• Workpiece diameter, max.: 200 mm 8 inch
• Workpiece length, max.: 200 mm 8 inch
• X-axis travel: 740 mm 29 inch
• Z-axis travel: 400 mm 15.5 inch
• Y-axis travel (optional): ± 30 mm ± 1 inch
•  Main spindle

1. Power rating 40% / 100%: 27 / 18 kW 36 / 24 hp
2. Torque 40% / 100%: 303 / 202 Nm 223 / 149 ft-lb
3. Speed, max: 4,500 rpm

• Turret tool stations: 12 qty
• Rapid-traverse rate X / Y / Z: 60 / 15 / 30 m/min 2,363 / 591 / 1,181 ipm
• Speed driven tools 6,000 rpm
• Torque driven tools: 30% / 100%: 27 / 15 Nm 20 / 11 ft-lb

On 12 November 2014, the VDW (German Machine Tool Builders’ Association) located in Frankfurt/Main, Germany, in cooperation with the German-Thai Chamber of Commerce (GTCC), invites Thai industry representatives and manufacturing experts to an exclusive German production technology Symposium in Bangkok.

Under the theme of “Innovation in Production Technology – Machine Tools from Germany”, a total of 14 internationally renowned German manufacturers present their products, solutions and services for an efficient and modern production. More than 200 participants and key stakeholders from relevant companies and associations of the Thai automotive- and supply industry, general engineering sector, machine and metal-working industry are expected to attend the high-level event at the InterContinental Hotel Bangkok.

German experts from the following companies will present their latest production technology solutions: Alzmetall Werkzeugmaschinenfabrik und Gießerei Friedrich GmbH & Co. KG, EMAG Holding GmbH, FFG-Werke GmbH, Gleason-Pfauter Maschinenfabrik GmbH, Heckert GmbH, Gebr. Heller Maschinenfabrik GmbH, Index Werke GmbH & Co. KG, Mikron GmbH, Profiroll Technologies GmbH, SAMAG, SIEMENS AG, SW Schwäbische Werkzeugmaschinen GmbH, Trumpf Werkzeugmaschinen GmbH & Co. KG, and United Grinding Group. Parallel to the exclusive presentations of the German companies, an individual ‘Business Match Making’ session between Thai and German companies takes place, which is organized by the GTCC.

Subsequent to the Symposium, the VDW invites all participants to a cocktail & networking reception acting as a platform for an informal exchange of opinions between the participants of the German delegation and the (potential) Thai customers.

The German machine tool giant EMAG is all set to showcase its revolutionary PMD 2 Grinding Machine at the upcoming exhibition AMB 2014. EMAG will present the PMD 2 for the first time at the international metalworking exhibition, the AMB, in Stuttgart. This machine from EMAG NAXOS-UNION provides for high output rates and impresses with its excellent price-performance ratio. The premier exhibition will be held from 16 – 20, September, 2014 in one of the biggest industrial hub Stuttgart.

International competition in the automotive industry is increasing apace. According to the latest studies so are the technological demands on vehicles – and with them the costs. But increasing prices in the face of stiff competition in the market is no longer easily defensible. In production terms, the costs incurred in the manufacture of passenger cars need to be reduced by three to four percent per year to retain current profitability levels – according to a McKinsey study. And this is a staggering percentage.  But what does it mean when it comes to manufacturing technologies? The example of the crankshaft clarifies the point. Here, a lot depends on the grinding process carried out on this core engine component. In future, the process needs to be of greater precision and subject to an even higher degree of efficiency. The grinding experts at EMAG offer an interesting alternative in their PMD 2 Crankshaft Grinder.

Actually, the prospects for the automotive industry internationally are very good. The next few years are expected to see noticeable growth (especially in the Asian growth markets). But it is also true that the competition is, in many respects, becoming more complex.  In Asia, for instance, new competitors are crowding onto the market. In addition to that, more rigorous national emission limits and safety requirements are leading to an increase in production costs. As a consequence, the eye of the planner is on the manufacturing technology. How can the cost increases be reversed? Crankshaft machining is again a good example. The efficiency and stability of the engine depends on this core component. The grinding process therefore includes a (work-intensive) fine-machining operation in the micrometre range. And this has always been a job for the expert – also where the manufacturer of the relevant technology is concerned.

New capital investment
The machine builders at EMAG have, for decades, relied on a high degree of knowhow in this sector. Among other machine tools, the company – with  headquarters in Salach, near Göppingen, Germany – also develops tailor-made grinding solutions for shaft-type components. The new machine PMD 2 complements their crankshaft grinder program. It is designed for the machining of crankshafts for passenger cars and features twin grinding heads that allow for the simultaneous grinding of two pin or main bearings in a single setup, using two grinding wheels. Its capacity covers small components of up to 500 mm length. “With this machine we are rounding off our range of crankshaft grinders to include the machining of smaller components,“ explains Dr Guido Hegener, Managing Director of EMAG Maschinenfabrik GmbH. “Up to now, our range of machines did not include a horizontal twin-head grinder for smaller crankshafts. This gap is now filled with the PMD 2, a machine the excellent price-performance ratio of which is also ideally suited to combat the increasing competition in the automotive industry.“

Outstanding precision guaranteed
The developers at EMAG have been able to fall back on tried and tested technologies. The basis for the PMD 2 is the well proven „Series 2“ of EMAG NAXOS-UNION and EMAG KOPP. These machines combine high-tech grinding technology with precision, great efficiency, process integrity and simple operation. That applies to the PMD 2 as well, of course, where two CBN grinding wheels machine crankshafts to the highest precision. To achieve this, the machine is equipped with a direct-driven workspindle, hydrostatic guideways and a linear motor in the X-axis, as well as an in-process measuring control that allows for roundness monitoring and correction in the machine. “The operator enters the relevant command in the control and the measuring process is carried out once the bearing has been ground. The software, developed by EMAG, then calculates the relevant correction values from the remaining roundness errors. This allows for the subsequent manufacturing processes to be successively optimised“, adds Mr Hegener.

Shorter cycle times – increased productivity levels
The technology also scores with its simultaneous use of two grinding wheels. The twin-tool process opens up a number of possibilities for the user, depending, of course, on component and machining requirements. Two pin bearings or main and pin bearing are machined simultaneously, leading to a reduction in cycle times. For instance, a four-cylinder crankshaft is machined in less than two minutes.  The grinding wheels can, if required, be arranged very close together, so that adjoining pin and main bearings can be machined simultaneously. Both, grinding spindles and work headstock are direct-driven. This further increases precision and productivity levels. “We have strung together a technologically very interesting package“, concludes Herr Hegener.

Flexible Configuration
The machine is also of compact but flexible construction. The enclosure includes, for instance, the electrical cabinet. Connecting up an automatic loading system is also no problem. And both, emulsion and oil can be used as coolants. “Flexibility was for us of great importance in using this technology“, confirms Herr Hegener. “We tailor the machine exactly to the customer’s requirements. Integration of the machine into an existing, complex production line is an important option. But we can also see the machine being used as a stand-alone solution, with manual loading“.

EMAG will present the PMD 2 for the first time at the international metalworking exhibition, the AMB, in Stuttgart. The international character of this trade show perfectly suits the strategy of the machine builder from Salach, as the machine can be used in a multitude of markets and production environments. “We are expecting great things from this flexible, efficient approach,“ explains Herr Hegener in conclusion. “The PMD 2 will give both Asian and European users a competitive edge. Component quality and production costs are gaining in importance everywhere. We are looking forward to showing our visitors at the AMB the quality of this technology.“

For more details contact EMAG Holding Gmbh