Innovations

Sustainabily can be achieved through a variety of measures. Durable machines with low energy consumption allow for efficient use of available resources and also employ the perfect production technology - optimized for both the customer and the environment.

The innovation

The vertical pick-up turning machine. In 1992, EMAG was the first manufacturer to build a vertical pick-up turning machine. The machines combine loading / unloading (automation), machining and measuring.

The result

Automatic loading of the EMAG vertical turning machines ensures that unproductive times are much lower than those generated on horizontal turning machines. Fewer machines are needed to do the same amount of work.

Sustainability

Durability and high productivity rates reduce the energy requirement per workpiece.

 

The innovation

MINERALIT® is a polymer granite with a vibration resistance eight times that of cast iron. The bases of most EMAG machines are made of MINERALIT®. The exceptional vibratory behavior of this material makes for fewer vibrations on the tool, leading to a better surface finish. Better vibration damping also reduces tool wear.

The result

The need for fewer replacement tools; and savings to be made in the machining process, as the surface finishes produced are of a better quality.

Sustainability

Machines bases in MINERALIT® require considerably less energy to produce than cast iron ones. MINERALIT® is also a certified road building material, which means that when machines are decommissioned, their bases can be shredded and reused as a subsurface material for road building.

 

The innovation

EMAG offers multi-functional machine tools that combine a number of processes on a single machine: turning, drilling, milling, grinding, gear cutting, etc., allowing for different processes to be used in the machining of the component.

The result

The same basic machine is used for the application of different machining processes. This increases flexibility and allows for a variety of workpieces to be processed on the same machine.

Sustainability

Increased use of the machine. The same basic machine can be used for the application of different processes. Therefore, a reduction in the number of machines used leads to a reduction in the energy required to manufacture the machines and a reduction in the energy required to machine the workpieces.

 

The innovation

The synchronous support grinding process combines, for the first time, flexibility and high productivity rates in the grinding of shaft-type components – with a noticeable grinding time reduction of up to 70% compared to conventional grinding processes. Two opposed CBN grinding wheels machine the same sector on the workpiece.

The result

Much faster machining of the workpiece. Outstanding surface finishes. Very high feed rates can be used.

Sustainability

A very fast process: the energy requirement per machined workpiece is significantly reduced. Also reduced are the unproductive times.

 

The innovation

The principle of “scroll-free turning”, developed by EMAG, is very different then any traditional turning work. During the scroll-free turning process the tool carries out a rolling motion on the workpiece, i.e. a diagonally positioned CBN cutting edge moves over a rotating workpiece. The cutting speed is governed by the workpiece rotation.

The overlaying motions of tool and workpiece ensure that the cutting action point advances constantly. This is not only ideal for the cutting edge; it also makes for a totally different load distribution than in the traditional turning process. The passive forces load is noticeably higher. Scroll-free turning is a very fast process – about 5 to 6 times the speed of previously used hard-turning operations and 2 to 3 times the speed of grinding. It also offers exceptional surface finishes, without any scroll marks. In other words, surfaces that previously had to be ground can now be scroll-free turned.

The result

Much faster machining of the workpieces. No surface finishing operation needed (exceptional surface finish, without scroll marks).

Sustainability

The energy requirement per machined workpiece is significantly lower. Dry machining processes require no coolant.