From new passenger cars with electric motors to the ongoing e-bike boom—the electric revolution in private transportation is picking up speed, and challenging production planners in the industry. How can the production of rotor carriers, rotor shafts, and similar parts be made even faster, more efficient, and precise in the future? At this year’s Technology Day in Gaildorf near Schwäbisch Hall in late November, the experts at EMAG ECM gave detailed answers to these questions. Technical lectures by scientists, ECM presentations, and live machine demonstrations showed clearly how electro-chemical machining (ECM) can be used to achieve exceptionally effective production processes for e-mobility and other industries. Interested visitors also had opportunity to discuss their individual challenges and questions with the ECM experts at EMAG.
Rotor Carriers, Rotor Shafts, etc.: Technology Day at EMAG ECM Showcases Solutions for E-Mobility and More!
01.11.2018 - Markus Isgro
Electric motor production creates new challenges for production planners in many companies: drive shafts and gearing components often have complex geometries and must be built with thin walls to save weight - and may even have bore holes with complex intersections. In addition, these components need to be precisely made with lean process chains. All of the above factors have contributed to the growing importance of electro-chemical machining in e-mobility and other industries. At their second ECM Technology Day, the experts demonstrated why EMAG ECM is so successful here. “We really got into the details at this event and were able to show how, in the future, it will be possible to produce even complex parts with a lean and cost-effective ECM process chain. The processes include ECM broaching, ECM drilling, and ECM deburring,” explains Richard Keller, member of the management board of EMAG ECM, Gaildorf. The ECM experts also explained the overall advantages of their method, which functions without contact between the tool and the workpiece: There is no heat warp and almost no tool wear, and the surface quality is very high. The ECM process creates no burrs, eliminating the need for additional deburring processes in many applications. This is independent of the material hardness.
Wide Range of Technologies Presented
The agenda covered many topics from theory and practice. For example, visitors had the opportunity to attend a presentation by the machine tool laboratory of RWTH Aachen about the status quo of the research into ECM technology, given by Dr. Andreas Klink, head engineer of the department for machining processes in the faculty of manufacturing process technology. EMAG presented a new, (P)ECM machine, at a significantly discounted price, in an early state of development, which will be ready for use in the near future. The agenda was rounded off by a variety of interesting ECM application examples, some demonstrated on live machines during a guided tour of the factory. In addition, visitors saw ECM machine types that are used as stand-alone solutions or as parts of modular systems—including the compact entry-level model CI 400, the modularly scalable and therefore extremely cost-effective CS stand-alone machine, the PO 900 BF, and the PO 100 SF for machining complex components for jet engines. “We are delighted about the amount of positive feedback from our visitors, who were excited about the event’s varied agenda and the high level of the technology and scientific presentations. The mix of scientific lectures, engineering know-how, and the opportunity for exchange with experts lent the event excellent practical value. On behalf of the entire team, I would like to thank all our visitors for this great day. We are already looking forward to the next occasion,” Richard Keller concludes.