• 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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Gear

Complete-machining of Gears

The machining process for gears utilizes machines of the VL platform, with four key operations carried out sequentially. Turning the first side and second side of the gear (OP 10 and OP 20) is done on VL 2 machines. A VLC 200 H then carries out the gear cutting process (OP 30) using a milling hob, with the concluding chamfering operation (OP 40) carried out on a VLC 100 C. The use of two different control systems (Fanuc on the VL and Siemens on the VLC) in one manufacturing system exemplifies the possibilities offered by combing different machines.

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Gear manufacturing: short machining times – exceptional output rates

Demands on the manufacture of transmission components continues to increase. Modern gearboxes are becoming smaller while the number of speed-gears increases, leading to a general increase in the quantity of all gears and toothed components required. It follows that these components must be produced at the highest precision and that calls for an ever increasing number of processes. Ideally, all of these processes should also be highly flexible, with a large variety of transmission components – such as shafts, gears, planetary gears and plate carriers – frequently being manufactured at the same site.

The technologies which successfully fulfil these demands have been developed by the gearing specialists from EMAG. With innovative machine designs they have expedited developments in the production of transmission systems.

Here are just a few examples:

  • The VL 2 Vertical Pick-Up Turning Machine for the fast and precise machining of gears: turning for the first and second side of the component
  • The VLC 200 H Vertical Hobbing Machine for the fast hobbing and deburring of gears
  • The VLC 100 C Vertical Chamfering Machine
  • The ELC 160 Laser-Welding Machine for the joining of synchronising ring and transmission gear
  • The Eldec Mind machine for the inductive hardening of gears

 

 

Advantages

    The advantages of VL- / VT manufacturing systems in the machining of gears

  • Tailor-made automation solutions for every application
  • Efficient workpiece flow, with short travels and short idle times
  • Modular manufacturing concept that can be expanded and adapted at anytime
  • Simple to operate manufacturing system that offers short resetting and maintenance times
  • Integrated development and construction from a single source – from machine to process and automation

Complete-machining of gears

Gears are machined in 4 setups using machines of the VL platform

Manufacture of gears for the automotive industry and its sub-suppliers

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