EMAG at EMO 2017 in Hannover was last modified: September 20th, 2017 by Janine Lahr
The HLC 150 H horizontal gear cutting machine by EMAG KOEPFER is the perfect complete solution for workpieces up to module 3 with a maximum length of 500 mm. It not only features all relevant gear cutting technologies such as gear hobbing, skiving, screw milling and worm skiving, it also includes press deburring and chamfering integrated into the machining area. As a result, an extremely wide range of workpieces can be finished without burrs – including gear and anchor shafts, steering pinions, planetary gears and worm gears.
High-quality gear cutting
Component quality and process reliability are ensured, first by the cutter head. It has a very rigid suspension, and always moves completely during the machining operation. The shift axis is based on the interpolation of two axes. This results in a large swivel angle for the cutter head, and a large shift path at the same time. This process is why the gear hobbing runs very smoothly and high gear cutting quality is guaranteed. Another important feature is the ability of the chips to fall downward freely, preventing chip build-up. For chip discharge, various solutions are available including scraper-belt or permanent-magnetic conveyors – with the option of a deep-bed filter with magnetic pre-separator drum for ferromagnetic materials, non-ferrous metals, and plastic.
Lower costs in gear cutting
The HLC 150 H also reduces costs in many ways: Its frequency-controlled hydraulic units are very energy-efficient. Next, the media supply is only activated when required. Furthermore, the quick-clamping system and easy accessibility of the machine allow changing of all tools in a very short time.
Integrating into lines by automation
Not least, the HLC 150 H includes a largely modular automation system: Lighter components up to 3 kg are handled by an integrated high-speed gantry loader with rotating twin gripper. For heavier workpieces up to 10 kg a V-shaped linear gripper is available. The machine can be integrated into a complete EMAG production line at any time.
Lightweight construction in the automotive industry is a fight for every pound. Every single part is investigated for whether it could be made even lighter. This is typically accomplished by using new materials of changing part geometries. Laser welding offers a surprisingly simple strategy, e.g. by enabling a stable connection between differential gear and ring gear. This saves screw connections and reduces weight by 1.2 kg – quite an accomplishment by the standards of the field.
The entire process chain at a glance
It is critical that laser welding is integrated in an end-to-end process that begins with cleaning and brushing and finishes with a final inspection. Developing systems for such processes is a specialty of EMAG Automation. Over the last several years, the company has sold more than a hundred laser welding systems. As systems suppliers, the engineers at EMAG familiarize themselves with the production process and develop the process chain. This drastically simplifies the planning on the customer side.
In-depth experience with components
Customers of EMAG Automation also benefit from its in-depth experience with components: Various
control gears, differential housings or clutch bodies are
machined using production lines from Heubach, near Schwäbisch Gmünd, Germany, even today. The process is always planned around the component – based on EMAG’s proven modular engineering concept. This is why the systems are unusually stable and efficient in every detail.
When precision counts in electrochemical machining, the tool cathode plays a significant role: Its shape determines the removal of material at the workpiece. Therefore, its design and precise production is a particularly important machining task in the micrometer range. For its development, EMAG ECM therefore has a large development area with a largely digital workflow.
The blisk tool in three steps
Currently, the specialists based in Gaildorf, Germany, are undertaking an important step in this context: The calculation of cathode shapes for blisk, disk, diffuser, etc. will be performed with the “EMAG Tool Designer” software, an in-house development. Toolmaking will involve the following three steps: Step one is a precalculation (IT0) of the cathode with the “EMAG Tool Designer”, based on the 3D geometry data of the component. After the cathode is completed, a first machining process starts in the PECM machine. Next comes an optical 3D measurement at the finished component. The measurement results are fed back into the “Tool Designer”. The program calculates the necessary corrections at the cathode.
Precision for turbine production
The corrected tool is then tested again, or the finished component is measured. If the values are correct, the development process is completed. At the end, the specialists will always provide their customers with a high-precision tool – a basic prerequisite for accurate production during the PECM process in turbine production.
The VLC 200 GT is loaded at by the integrated pick-up spindle. The process starts with hard pre-turning of the shoulder and the bore hole in quick succession. Only a few micrometers of material are then left to be removed from the automotive gear by the subsequent grinding process, using either aluminum oxide or CBN grinding wheels.
Transmission manufacturing is among the most innovative areas of passenger vehicle production: This central component has to ensure a high level of driving dynamics, while keeping fuel consumption low at the same time. Transmissions are therefore becoming smaller and lighter, and provide a higher number of speeds. The individual gearwheels are a main focus of the developers. Their production in extremely high volumes requires a high level of efficiency—at high precision, high speed, and highly controlled.
Motion, mobility, and innovations are crucial elements of the EMAG Group philosophy. We aim to provide our industry partners with the best manufacturing solutions to complete their vision.
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?
Maximum Efficiency in Shaft Production. Short cycle times, high precision and safe processing are among the outstanding attributes of shaft machining on the turning machines of the VT series. These lathes literally turn the classical horizontal machining process on its head.