• Articulated cage—produced on an EMAG vertical turning center VTC 100-4
    Articulated cage
  • PECM for the machining of blisks
    Blisk
  • Brake disc
  • Cam
  • Composite camshaft for a small engine
    Composite camshaft (joining)
  • Automobile crankshaft machined on the PM 2 series.
    Crankshaft (automobile)
  • Crankshaft (for small engines)
  • CV joints make high demands on the machining technology. Core components: Kingpins, articulated cage, joint ball
    CV Joints
  • Dies
  • Differential pinion—precision machining on VL machines
    Differential pinion
  • Differential housing
  • Distributor flange
  • Feed screw
  • Flange manufactured on VL 2 lathes
    Flange
  • Gears are machined on EMAG VL series machines
    Gear
  • Gear shaft
  • Composite gear shaft manufactured with high precision by the use of EMAG heat shrink assembly technology.
    Gear shaft (joining)
  • Gear shaft (laser welding)
  • Gear with synchronising wheel
  • Gear of an automobile gearbox manufactured on a VLC 200 H
    Hobbing gears
  • Injector body
  • Machines by the EMAG Group for Kingpin production
    Kingpins
  • Master brake cylinder
  • To machine pistons with precision poses a particular challenge for all manufacturing solutions
    Piston
  • Pump ring production on the high-precision SK 204 grinder
    Pump ring
  • Railway wheel manufactured with precision on VLC 1200 turning centers
    Railway wheel
  • Roll rings are precision components
    Roll ring
  • Screw
  • Sprocket
  • Sprocket (Manufacturing System)
  • Steering pinions can be machined with great precision on the EMAG VT machine
    Steering pinions
  • Triple-sector clutch
  • Surface layer hardening an armature shaft on an eldec MIND 750
    Armature shaft
  • Input shaft
  • Balance shaft
  • Induction hardening through precision control
    Hydraulic Valve
  • Camshaft
  • Hardening shifter shafts with induction hardening
    Shifter Shaft
  • Surface layer hardening with the eldec hardening machine
    Wheel Hub
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Dies

Electro-chemical Machining (ECM) for Producing Dies

Integrating complex 3D geometry, like that in precision dies of high-tensile materials, places very tough demands on machining technology.

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Design freedom when configuring dies

Components with up to eight axes are electro-chemically produced in the PT series machines with no thermal impact. Even the most demanding 3D structures are possible. Feeds of up to 5 mm/min are achieved in the electro-chemical (ECM) rough-machining area. The planar machining or parallel machining of 20 to 30 components makes it possible to realize crucial cost savings with moderate to significant unit numbers. Production accuracy to under 20 micrometers can be achieved. Plus, ECM tools have a very long life.  This means a considerable production cost factor is eliminated in comparison with clamping methods. In contrast to erosion (EDM), ECM does not cause micro-fissures, an effect that impacts the stability of the component – a factor that is especially important in high-performance press tools.

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Erosion (EDM) vs. Electro-chemical Machining (ECM)

  • EDM scores points when producing prototypes because of its limited equipment requirements and lower complexity in terms of devices and electrodes.
  • As the unit numbers increase, ECM processes benefit from the fact they operate without tool wear and, as a result, produce long service life.
Productivity comparison EDM vs. ECM

EDM vs. ECM productivity comparison: Electro-chemical machining scores points in particular with high unit numbers because ECM operates without tool wear

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