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 design and development of coated brake discs are becoming increasingly important in the automotive industry. The main driver behind this shift is the need to reduce brake dust emissions, as mandated by international regulations like GTR 24 and the Euro 7 standard. These regulations set strict limits on particulate emissions (PM10): capping them at 7 mg/km for passenger cars and as low as 3 mg/km for electric vehicles. These standards will be enforced across the European Union starting in November 2027, with a similar regulation expected to take effect in China between 2028 and 2030 under the National 7 standard.
To meet these emission targets, manufacturers are increasingly turning to coated brake discs, with Laser Metal Deposition (LMD) emerging as a promising technology. However, the precision required to manufacture these complex components presents significant challenges. The key to achieving high-quality, cost-effective brake discs lies in the coordination between the laser coating process and the subsequent grinding process.
When Vince Zamora first joined EMAG as an intern in 2022, the office was still quiet from the effects of COVID-19. But even in those early days, one thing was clear – this was a place where young engineers could gain real experience, take ownership of their work and grow alongside a supportive team. Today, Vince is a full-time mechanical engineer at EMAG, and his journey from co-op student to team member highlights the value of hands-on learning and a company culture built on collaboration.
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.
The automotive industry is facing a major challenge: the Euro 7 standard stipulates strict limits for particulate matter emissions. Cars will then only be allowed to emit around three milligrams of particulate matter per kilometer – a drastic reduction compared to today’s values of up to 40 milligrams. To achieve these ambitious targets, car manufacturers are increasingly relying on innovative technologies such as coated brake discs.
Laser cladding is a promising process for manufacturing these ultra-modern brake discs. In this application, a special material powder made of stainless steel and hard carbide is welded onto the surface of the brake disc using a laser. The result is brake systems that not only drastically reduce particulate emissions, but also minimize wear and prevent corrosion.
However, the design and development of this new coating technology also creates new challenges in post-processing. With the VLC 450 DG grinding machine, EMAG offers a specialized solution for the machining of these high-tech brake discs.
We spoke with Jannik Röttger, Head of Grinding Technology at EMAG, about this innovative technology and EMAG’s response to the challenges of the Euro 7 standard.