Modular – Chucked Components – VL/VM
VL 100 GT
- Workpiece dia., max.: 100 mm | 4 in
- Chuck dia., max.: 160 mm | 6.5 in
- Swing diameter: 210 mm | 8.5 in
Precion finishing of small CNC chucked components in batch production
The production of small CNC chucked components is associated with high volumes in many industries – often running into the millions per year. Workpieces such as gear wheels, planetary gears, sprockets, cam rings, pump rings, individual cams, and shaft generators must undergo precision finishing after hardening to achieve the required dimensional and surface tolerances. At the same time, demands for dimensional accuracy and surface quality are constantly rising.
This is exactly where the VL 100 GT comes in: it combines hard turning and grinding in a compact, automated unit and enables complete-machining in a single setup. Manufacturers benefit from short cycle times, low tooling costs, and reproducible surface finishes – even for the smallest geometric details.
Design advantages of the vertical configuration
The VL 100 GT follows EMAG’s signature principle of vertical machining. The workpiece spindle is positioned at the top and independently picks up workpieces from the integrated conveyor belt using a pick-up process. Compared to horizontal machines, this design offers three specific advantages that directly impact productivity and component quality:
- Unhindered chip flow: Chips and grinding slurry fall freely by gravity out of the work area. There is virtually no chip accumulation on the workpiece or guideways. This reduces thermal interference, prevents surface damage, and minimizes cleaning requirements.
- Compact footprint: The VL 100 GT requires only about 9.6 square meters of floor space. This small footprint enables multi-machine operation – a single operator can oversee multiple machines simultaneously, significantly reducing labor costs per workpiece.
- Optimal accessibility: The work area is designed so that setup operations can be performed quickly and ergonomically. This shortens changeover times when switching to new components and increases machine availability.
The MINERALIT® machine base as a quality factor
The machine base of the VL 100 GT is made of MINERALIT® polymer concrete. This material offers eight times higher vibration damping compared to conventional cast iron. For the user, this means higher surface quality of the machined workpieces, longer service life of the grinding tools, and overall more stable process control. Especially in fine machining, where surface values in the range of Rz < 1.2 µm are required, the vibration damping effect of the machine base is a decisive quality factor.
Integrated pick-up automation for short non-productive times
The main spindle of the VL 100 GT handles the loading and unloading of workpieces itself. The process is clearly structured: the work spindle moves to the pick-up station, picks up a raw part from the circulating conveyor belt (O-Automation), and moves it into the work area. After machining, the spindle places the finished part back onto the conveyor belt and immediately picks up the next raw part. This results in three concrete advantages for the user. First, separate loading robots or gantry loaders are no longer needed – eliminating additional capital investments and footprint requirements for external automation components. Second, the short travel distances between the pick-up station and the work area lead to very short chip-to-chip times. Third, the next batch can be placed on the conveyor belt while machining is still in progress, thereby reducing machine downtime to a minimum.
Flexible automation options for link-up of production lines
As an alternative to O-Automation, the VL 100 GT can also be equipped with shuttle automation for feeding and removing components. This enables seamless integration into linked production lines, for example in combination with EMAG lathes from the VL or VT series. This results in extremely compact manufacturing systems that can be flexibly adapted to the respective workpiece range.
Freely configurable work area for a wide range of machining requirements
The work area of the VL 100 GT was designed from the ground up to be flexibly adapted to the respective machining requirements. Depending on the workpiece requirements, various machining modules can be integrated. The configuration is carried out in close consultation with the customer to suit the specific workpiece range.
Overview of available machining modules
- Internal grinding spindle: Both corundum and CBN grinding wheels can be used for precision grinding of bores.
- External grinding spindle: For external cylindrical grinding of cylindrical surfaces, flat shoulders, and contours.
- Solid steel holders for hard turning operations: One or two solid steel holders enable hard turning of end faces and areas that can be machined faster and more economically by turning than by grinding.
These modules result in practical configurations: pure internal grinding, pure external cylindrical grinding, dual internal grinding, the combination of turning and grinding, or complete machining with turning, internal grinding, and external grinding in a single setup.
Out-of-round grinding via linear motor drive
The current generation of machines integrates a linear motor drive on the X-axis. This enables machining of out-of-round contours—such as cam profiles or eccentric surfaces – with high dynamics and precision. Compared to conventional ball screw drives, the linear motor offers significantly higher acceleration and positioning accuracy while operating with no-wear operation. For the user, this considerably expands the range of machining requirements that can be met on the machine.
Integrated measurement for seamless quality inspection
The VL 100 GT is equipped with an integrated measuring probe positioned between the work area and the pick-up station. In this location, it is protected from contamination by cutting fluids and chips while remaining integrated into the material flow. Since the workpiece remains in the setup during the measurement process, measurements are possible both before and after machining, as well as intermediate measurements between individual machining steps.
Modular design based on the VL platform
The VL 100 GT is based on the modular system of the EMAG VL series. Identical base machines can be configured for different manufacturing tasks without the need to learn fundamentally new operating concepts or build up separate spare parts inventories. Uniform operation and part programming across the entire machine family reduce training requirements and simplify integration into existing production environments.
Frequently asked questions
- For which workpieces is the VL 100 GT suitable?
- Which machining processes can be combined on the VL 100 GT?
- What surface finishes does the VL 100 GT achieve in fine machining?
- What advantages does the vertical design offer over horizontal machines?
- How does the VL 100 GT’s pick-up automation work?
- Can the VL 100 GT be integrated into link-up production lines?
The VL 100 GT is designed for fine machining of turned parts with diameters up to 100 millimeters. Typical workpieces include gear wheels, planetary gears, sprockets, cam rings, pump rings, individual cams, and shaft generators for tension shaft drives. The machine is particularly suitable for medium- to large-scale production with high requirements for dimensional accuracy and surface quality.
On the VL 100 GT, hard turning, internal grinding, and external grinding can be combined in a single setup. Depending on the workpiece, the work area can be equipped with an internal grinding spindle, an external grinding spindle, and one or two block tool holders. This combined machining reduces cycle times, prevents reclamping errors, and ensures high positional accuracy between the machined surfaces.
The VL 100 GT reliably achieves surface roughness values in the range of Rz < 1.2 µm. This is made possible by the vibration-damping MINERALIT® machine base, the optimized combination of hard turning and grinding, and the adaptive grinding process control. The surfaces are free of runout and thus meet the requirements for highly stressed functional surfaces.
The vertical design of the VL 100 GT offers three key advantages: chips and grinding slurry fall freely out of the work area by gravity, which reduces thermal interference and protects surface quality. The footprint of approximately 9.6 square meters allows for operation of multiple machines. In addition, setup procedures can be performed quickly and ergonomically, which increases machine availability.
With pick-up automation, the VL 100 GT’s main spindle handles the loading and unloading of workpieces itself. It moves to the pick-up station, picks up a raw part from the circulating conveyor belt (O-Automation), and moves it into the work area. After machining, the spindle returns the finished part and immediately picks up the next raw part. This eliminates the need for separate loading robots and minimizes chip-to-chip times.
Yes, the VL 100 GT can be used both as a standalone machine and within interlinked production lines. As an alternative to O-Automation, shuttle automation is available for feeding and removing components. In combination with upstream lathes from the EMAG VL or VT series, compact manufacturing systems are created that cover the entire process from soft turning to hard finishing.
Advantages VL 100 GT
- Complete machining in a single setup eliminates reclamping errors and ensures maximum positional accuracy.
- Freely configurable work area allows adaptation to virtually any machining requirement—from pure grinding to combined machining.
- Integrated pick-up automation enables short non-productive times and high machine availability without additional automation components.
- Vertical design with a MINERALIT® machine base guarantees unobstructed chip evacuation, outstanding vibration damping, and the highest surface quality.
- Combined hard turning and grinding reduces cycle time, lowers tool wear, and enables twist-free surfaces with Rz < 1.2 µm.
- Small footprint of approx. 9.6 m² enables multi-machine operation and efficient use of floor space.
- Modular design on the VL platform ensures uniform operation, flexible configuration, and broad control compatibility.
- Linear motor drive on the X-axis enables precision out-of-round grinding of cam profiles and eccentric surfaces.
- Comprehensive grinding sensors and measurement technology ensure stable, reproducible process control with integrated quality inspection.
Workpieces
The Right Manufacturing Solution for Every Workpiece
Cam
Gear
Machining from raw blank to finished gear– a process that used to take several departments within a shop using multiple experienced operators. Now this process can be done with a pair of digitally…
Gear wheels (e-bikes)
Regardless of whether they are made of plastic or metal, EMAG solutions can be used to manufacture a wide variety of gear wheels. Thanks to the wide range of technologies available at EMAG, we can…
Planetary Gears
Sprocket
The combination of different processes within a single machine and a single setup offers enormous savings potential in terms of cycle times. With the machining of chucked components up to 100 mm in…
Wave Generator
The wave generator is the input component in the strain wave gear. It consists of a thin-walled bearing structure (outer ring elastic, inner ring fixed on an elliptical cam) and defines the positive…
Technologies
Complex Manufacturing Systems from a Single Source thanks to a High Range of Technologies
Grinding, besides drilling, is one of the best known chip removal production methods because it is also frequently used during daily activities.
The combination of a number of processes – such as hard turning and grinding – on a single machine, allows for the exploitation of considerable…
Vertical turning is a machining process for metal components. EMAG was one of the first machine tool manufacturers to use the vertical turning process…
