Joint housings are among the most technically demanding components in automotive drivetrains. Together with inner races, ball cages, and outer races, they form the basis for CV joints, which enable uniform power transmission between two axles—even with varying angles and length compensation. The manufacturing quality of the ball tracks in these components directly determines the functionality, smoothness, and service life of the entire drivetrain.
With the rise of electric mobility, the focus in manufacturing is shifting significantly: Components that could “run along” in internal combustion engines due to masking noises and vibrations are evaluated much more critically in electric drives. The reason is simple: The internal combustion engine generates a broad spectrum of noise that masks many background sounds. In electric drives, this acoustic “background noise” is largely absent, making deviations in shape, position, and surface significantly more noticeable.
The production of steering pinions poses a particular challenge in the modern automotive industry. These precision gear components are indispensable parts of steering systems and must meet the highest quality standards while also being produced economically in large quantities. The combination of required dimensional accuracy, surface finish, and process stability demands specialized manufacturing solutions.
In this interview, Konstantin Ungefuk, Head of the Gear Cutting Soft Business Unit at EMAG, explains the complex process chain involved in machining steering pinions. He provides detailed insights into every machining step – from turning the raw-parts to soft-state gear hobbing, precision grinding of the bearing seats after hardening, and the final skiving of the hardened tooth profiles.
Strain wave gearboxes are an indispensable part of precision drive systems. They play a central role in robotics, automation technology, and positioning axes with high accuracy requirements in particular. But what exactly is the operating principle behind this gear technology, and why is it particularly suitable for compact, low-backlash drive solutions?
Wave generators are central drive elements in strain wave gears, which are used in robotics in particular due to their high reduction ratios and compact design. The component consists of a ball bearing with an elliptically shaped outer ring, which is mounted on a shaft and typically acts as the input side of the gearbox.
Producing these components presents significant technical challenges for manufacturers: The required shape tolerances in the single-digit micrometre range combined with complex elliptical geometries and thin-walled structures require specialized manufacturing strategies and highly capable machine tools.
Ball joints are an integral part of modern vehicle construction – they perform safety-related tasks, particularly in chassis and steering systems. How do they work, and what requirements does this place on the precision manufacture of the ball pin?
Experience the new generation of EDNA Feature Correction and EDNA Production Status.
EDNA Feature Correction is a core component of EDNA ONE and enables the manual or automatic adjustment of production features in real time. This ensures that product quality remains stable over the long term and process deviations can be corrected immediately.
EDNA Production Status is a central module of EDNA ONE and displays the current status of a machine as well as the overall production progress in real time. Operators receive a clear overview of active programs, upcoming work steps and possible downtimes. This makes machine operation more transparent, reaction times are reduced and production can be controlled much more efficiently.
The manufacturing industry faces the challenge of using production space more efficiently while also reducing process times. When machining flange parts, such as differential housings, several separate machining stations are required in conventional production. The VT 200 with counter spindle option shows how modern turning machines can address these challenges through process integration.
EWS Weigele is known for its precision tool holders. What is less well known is the company’s technical standards and vertical manufacutring range – including the hard machining of its own bevel and toothed gears. A modernized VSC 400 DDS from EMAG plays a key role here. In this interview, plant manager Christian Schurr explains why the retrofit of this machine was a decisive step for EWS – technically, organizationally and strategically.
With the introduction of Sinumerik One, EMAG continues its commitment to the latest CNC control technology from Siemens. Replacing the proven 840D sl platform, SINUMERIK One serves as the foundation for the next generation of digitally connected manufacturing systems. Combined with EMAG’s new WinCC Unified-based software, this future-ready control system delivers maximum performance, intuitive operation and seamless integration of smart data applications.