Machining, AMB, EMAG

EMAG is making industrial production more flexible, productive and sustainable

Maximum productivity and sustainability, with flexible machine solutions for many different production tasks and sectors – this best summarizes the EMAG Group’s focus for this year’s presence at the AMB from September 13 to 17 in Stuttgart. At the trade fair, the specialists present their technological scope, from turning, grinding, and hobbing to robot-based automation to laser and ECM machining. And: Data-based analysis and optimization of the production process will continue to be a key focal point at EMAG. Accordingly, visitors to booth B51 in hall 4 get to see a range of IoT products that can, for example, reveal the energy consumption of a machine or its status.

Under the name EDNA (short for “EMAG DNA”), the machine manufacturer has been advancing data-based networking of its production solutions for some years. This makes it possible, for example, to determine the status and OEE values of a machine with great accuracy and get information on its current production output. At the AMB, EMAG is now presenting the next IoT development step to the visitors – an Energy Monitor with which an unusually high energy consumption (for example per workpiece) can be detected at any time. “Sustainability through transparency,” is the motto. In these times, where the world is facing a climate crisis and a growing energy crisis, this is becoming increasingly important.

Completely dry machining

The mechanical engineering solutions that EMAG is showing are similarly efficient and sustainable. The SG 160 from EMAG SU is particularly impressive. It machines turning blanks in a completely dry process that combines hobbing and gear generating grinding in a single clamping operation. Subsequently, these gears are nitrided and after the drilling work is complete, they are finished on a turning machine. This not only saves an enormous amount of space in the manufacturing hall, but also greatly reduces the investment costs, as this process would customarily require separate machines for hobbing and generating grinding respectively. Additionally, the process time is much shorter than when individual processes are used, because both processes are fine-tuned to each other. The new machine makes use of two procedures on two different tool spindles: hobbing for the soft machining and dry generating grinding (finish grinding). A huge amount of electrical energy is saved in manufacturing, since the alternative – wet grinding – always necessitates a filter system, cooling, and oil mist extraction. These are all “energy guzzlers” that are not needed for dry machining with the SG 160.

The VLC-GT series, which EMAG is also presenting at the AMB, offers a similar combined machining operation. With these machines, different technologies such as hard turning, internal and external grinding, milling, reaming, or honing can be combined, and the machining in a single clamping operation ensures that the components are of high quality. Using the pick-up principle and combination machining, not only chucked components but also short shaft parts can be produced on the VLC 200 GT.

EMAG VLC GT multitasking machining center
With the SG 160 machine from EMAG SU, gears undergo completely dry grinding, which saves an enormous amount of energy.

Efficient machining of large components

A literally large solution in the field of vertical turning is the VSC 500, which EMAG will demonstrate live at the AMB – a platform for the production of large and very heavy workpieces, such as those found in the commercial vehicle sector, from brake drums, transmission and engine components to wheel hubs. These components undergo turning, drilling, sinking, reaming, milling, and threading processes in the very rigid machine, depending on the specific requirements. Even more productivity is guaranteed by the DUO variant for machining in two clamping operations (OP 10/OP 20).

Innovation thrives on electromobility

An example of sustainable technology advanced by EMAG’s customers is electromobility, for which EMAG has provided many production solutions in the past years. At the AMB, the specialists are presenting some of these, for example a turnkey manufacturing line for a two-piece rotor shaft that is produced in a total of seven successive operations. Another technology that is of great interest within the context of sustainable products is laser coating of brake discs with a machine from EMAG LaserTec, which can smoothly be integrated into complete production lines with upstream turning and downstream grinding processes. This makes it possible to create wear- and corrosion-free brake discs that produce less fine dust. Additionally, EMAG LaserTec is presenting its new highly flexible ELC 1200 V machine platform, for individual applications from laser cleaning and laser welding to laser hardening.

EMAG VLC GT multitasking machining center
The VLC-GT series from EMAG combines many different technologies, such as turning, internal and external grinding, milling, reaming, or honing.

Large range of technologies

The large range of technologies and applications mastered by the EMAG Group is being showcased at the AMB for example in the form of the W 11 CNC cylindrical grinder from EMAG Weiss, which enables extremely precise machining of individual parts, prototypes, and small series, as well as the VTC 200 CD shaft turning machine, which features a center drive for simultaneous 4-axis machining with short cycle times. Additionally, the K 160 hobbing machine demonstrates that EMAG’s range of effective production solutions is not limited to the automotive industry: The machine is ideal for small gearing up to module 2.5, such as those used in hand tools, for example cut-off saws. Electrochemical machining (ECM) also plays an important role in a wide variety of industrial sectors. EMAG’s specialists have created a solution for manufacturing complex internal geometries or internal gearing – and high-strength materials or large quantities are no problem at all. How exactly does this work? AMB visitors can find out first-hand.

New automation cells

Another focal point at EMAG’s trade fair booth is the topic of automation, because the machine manufacturer from the south of Germany has developed new automation cells with robots. The entire production process is getting faster, more cost-efficient and more reliable, with the pick-up technology from EMAG being particularly suitable for this approach, as the machines have an internal automation system, which serves as a good basis for having them loaded and unloaded by robot solutions. The parts are, for example, fed in pre-aligned in baskets or drawers, chaotically as bulk cutoffs, or by means of infeed and outfeed conveyors.