With around 15 percent growth per year, the Czech supplier ZLKL has an impressive success story. Advanced production technologies with automation components play a decisive role in this. For example, around 25 EMAG machines are in operation at ZLKL’s Czech sites. Karel Zeman, Senior Manager Machining at ZLKL, discusses his company’s formula for success.
Vertical Turning Machine
For over 30 years, Bäringhaus & Hunger, based in Grünhainichen near Chemnitz, have been active in the part manufacturing industry – experiencing growing success with the production of high-precision turned and milled parts. About 90 percent of orders received at Bäringhaus & Hunger come directly from suppliers in the automotive industry. From almost the very beginning, EMAG has played an important role in this as a mechanical engineering partner, and currently have over 20 machines on the Bäringhaus & Hunger shop floor. How did this partnership develop and why is it still so important today? We spoke with partners, Matthias and Sebastian Hunger, the second generation of the family to run the company, about the secret to their company’s success.
Interprecise Donath GmbH, based near Fürth, Germany, develops and produces rolling bearings that are used in a variety of machines and gears – an extremely precise task that involves just a few micrometers and requires special surface qualities. For about three years, VL vertical lathes from EMAG have been used for this machining, achieving lower unit costs in the soft and hard machining of many components. We sat down for a conversation with Interprecise Managing Director, Christian Witte, about the market challenges and advantages of pick-up technology.
Scroll-free turning is one of those machining technologies that is very difficult to describe in words, so it’s a good thing we have video and pictures! Take a look at the video below for an overview of how scroll-free turning works:
The VL 1 TWIN has set the new standard for the high-output, simultaneous machining of workpieces with a maximum dimaeter of 75 mm (3 in). This turning center has two main spindles in one machining area that are able to simultaneously machine two identical workpieces – resulting in substantially increased output quantities, and lower unit costs.
How can commonly mass-produced transmission components, such as planetary gears be produced even more efficiently? The EMAG Group provides a customized answer to this question with the development of the twin-spindle pick-up turning center, VL 1 TWIN. It machines two identical components simultaneously in the same machining area. This technology opens up a wide range of possibilities: When two machines are combined in a line, the planetary gear can be machined from two sides—and all that is completed with shorter cycle times. What exactly does the line solution for planetary gears look like?
The Swiss company Humbel has been involved in gear production since 1928—specializing in particularly sophisticated types of gears and transmission components, eventually evolving into a full-service supplier. At their facility in Kradorf, approx. 20 kilometers (12 miles) from St. Gallen, they produce both individual parts as well as complete assemblies. The company recently expanded their machine inventory to include a VL 4 vertical turning center by EMAG. — We spoke with Alex Humbel, Managing Director of Humbel Zahnräder AG in Kradolf, on the challenges facing gear producers, the importance of E-mobility, as well as their company strategy.
The EMAG Inverted Spindle Pick-Up Lathe process provides for a significant improvement in accuracy versus that of a sub-spindle lathe.
Lathes with sub-spindles pass a part from one rigid work holding system to another. This does not allow for any misalignment of the two spindles. The first spindle cannot release a part until the second spindle has a secure grip on it. Allowing for mismatches on a split turned dimension such as a bore. The accuracy and quality of the workpieces that are produced from this system are compromised because of this process.
Today’s competitive talent marketplace requires small and medium contract manufacturers and OEM’s to make the most of the talent they have. Skilled, experienced machinists are hard to find and having them tied up hand-loading parts into a lathe is seldom the best use of talent. So – how does a successful small to mid-sized shop meet their customers’ production requirements with the existing talent pool?
EMAG’s Standard Modular Vertical Turning Solutions for chucked and shaft like components continue to gain market share within North America.
For years EMAG has continued to develop and invest in new technologies that make them the leading OEM of Manufacturing Systems for Precision Metal Components. We’ve become known world-wide for our Vertical Turning technology along with our ability to provide complete process chains to the world’s leading Automotive OEM. We’ve become the prominent leader in gear box, engines, and chassis solutions within the automotive industry but can also provide solutions within Energy, Aerospace, Agriculture, Construction and Oil Field.