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.
The machining of thin-walled workpieces is a complex task in manufacturing technology. Hardened rings and gears in particular exhibit considerable shape deviations after heat treatment. These components typically have elliptical, potato-shaped or triangular contours instead of the required circular shape. During subsequent lathe machining, conventional clamping systems often fail to achieve the required roundness tolerances.
The central challenge lies both in the deviation of the clamping diameter and in the interaction between workholding technology and cutting forces. While traditional diaphragm chucks, collet chucks or centering and face chucks can guarantee a mechanical fixation, out-of-round workpieces inevitably deform, leaving free arc segments between the clamping points. At these points, the lathe tool presses the thin-walled component outwards, which leads to additional shape deviations after spring-back. Even with optimized workholding technology, conventional processes often reach their limit at roundness values of 20 to 30 µm.
The automated production of turned parts in medium and large batch production requires CNC turning machines that combine productivity, process reliability and cost-effectiveness. The MSC 5 DUO from EMAG’s Classic series addresses these requirements with a machine configuration consistently designed for automation. As a fully automated CNC lathe with a double-spindle concept, the machine is positioned in the compact manufacturing cell segment for workpieces up to 120 mm in diameter and 85 mm in length.
Daniel Rujanoski is Director of Global Sales & Applications at EMAG LaserTec and is responsible for technical sales and the Laser Application Center. In this interview, the expert in laser welding technology explains the technical features and cost-saving advantages of the new ELC 6i – a standardized laser welding cell for powertrain components.
Stepped planetary gears are a key component in the drivetrains of electric vehicles. These components must meet high precision requirements while remaining cost-effective for series production. The combination of geometric complexity and tight tolerances demands sophisticated manufacturing concepts.
Double helical gears are a special type of gear in which two helical gears are arranged in a mirror image configuration on the same shaft. This design can withstand high loads and is significantly more cost-effective to manufacture than herringbone tooth profiles. Double helical gearing combines the advantages of helical gearing, which can absorb high loads, with the additional benefit of compensating for axial forces through its mirror-image arrangement.
The USC 21 from EMAG is a high-performance special-purpose machine for the precise machining of pipe ends and OCTG components. It reliably and flexibly handles the full range of API, GOST, integral and premium threads – with maximum production accuracy.
Turning balls, especially in safety-critical areas such as the automotive industry, places the highest demands on precision, repeatability and cycle time. Components such as ball pins in ball joints play a central role in steering and chassis. Their production requires state-of-the-art turning technology – especially when it comes to large quantities and economical processes.
The requirements for CNC lathes are clearly defined: maximum process reliability, high machining precision, flexible application options and easy integration into automated production lines. A well-thought-out machine concept is particularly important for workpieces that require machining on both sides as well as additional milling or drilling. The HSC 1 from EMAG has precisely these aspects in mind. In this interview, Peter Gröner, Product Manager of the Turning Business Unit at EMAG, explains the technical features, the range of applications and the design considerations behind this machine.
When it comes to cylindrical grinding, there’s no shortage of strong options – and a few persistent myths. At its core, cylindrical grinding is one of the most precise and consistent methods of finishing round parts. Yet, many manufacturers hesitate to explore it further, often due to outdated assumptions or misconceptions. Let’s take a closer look at some of the most common myths and why they don’t hold up today – especially with machines like EMAG’s WPG 7 on the market.
“CNC is Always better Than Manual Grinding”
There’s no doubt that CNC grinding brings repeatability and automation to the table – but that doesn’t mean manual grinding is obsolete. In fact, experienced machinists can often achieve impressive results with manual machines, especially for low-volume work or one-off components that demand hands-on finesse. Manual grinding offers flexibility and tactile control that some applications still require.
The real takeaway? It’s not about choosing between CNC or manual – it’s about having the right tool for the job. A machine like the WPG 7 is built with this in mind: while fully CNC-controlled, it’s designed to offer easy operator access and intuitive setup, making it ideal for both seasoned manual grinders and shops ready to transition to more automated processes.
“Automation is Only for High Volume”
This myth is especially common in small to mid-sized shops, where automation is often seen as costly or overkill. But with today’s modular grinding platforms, automation isn’t an all-or-nothing commitment. It can start with something simple as programmable workholding or automated part loading.
The WPG 7 is a prime example – it’s and OD cylindrical grinding machine that can be equipped with automation options, but it also performs great as a stand-alone unit. Shops can start manual and scale up when the workflow demands it. In many cases, even limited automation can significantly reduce cycle times and free up skilled labor for more critical tasks.
The WPG 7 cylindrical grinding machine offers modular automation options – from simple loading to full robotic integration – ideal for growing shops.
“Grinding Machines Take Too Long to Set Up”
While it’s true that traditional grinding setups could be time-consuming, modern cylindrical grinding technology has come a long way. Machines like the WPG 7 are engineered for fast changeovers, with a compact footprint and intelligent controls that make setup more intuitive than ever.
Thanks to features like quick-change tooling, user-friendly interfaces and minimal mechanical adjustments, shops can move from part to part without excessive downtime. For job shops or OEMs that handle multiple part families, this can mean the difference between a profitable run and wasted hours.
The WPG 7 grinding machine features a large front door, supporting fast changeovers and intuitive operator access.
Clearing the Air – and Grinding Smarter
Cylindrical grinding doesn’t have to be intimidating, expensive or inefficient. By challenging outdated assumptions, manufacturers can unlock new efficiencies and capabilities – whether they’re producing hundreds of parts or just a handful.
The bottom line? The right grinding machine doesn’t just cut – it fits. And with machines like the WPG 7 offering a blend of flexibility, automation-readiness and quick setup, there’s never been a better time to rethink what cylindrical grinding can do for your shop.
WPG 7 cylindrical grinding machine designed for flexible, efficient machining – ideal for both small batches and high-mix production.