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Precision Production of Small Components



Twelve turning or up to 12 driven drilling and milling tools can be employed to carry out a large number of operations in a single setup. The machine can also be equipped with optional Y-axis.

O-automation is used to transport the workpieces, with the pick-up principle employed to load and unload them.

The workpieces are loaded either directly into the carrier prisms or into special workpiece receptors located inside the prisms then transported into the machining area of the VL 2.

A measuring probe located outside the machining area carries out quality control procedures. The automatic measuring cycle takes place after machining and before the workpiece is returned to the conveyor belt, acting as an in-process quality control measure.

Generously designed maintenance and service openings at front and rear provide easy access

"Today in an industrial production environment you encounter the expression `downsizing' whereby the term describes more than just the scaling down of the passenger car engine and its displacement," said an EMAG spokesperson. "There is a change too in the direction the production of electric motors and pumps for the energy industry and for general mechanical engineering is taking with components getting smaller and smaller. However, the trend towards downsizing increases demands for greater precision and that makes the manufacture of small components a real challenge. Shrinking components and new smaller components present a particularly complex task for the mechanical engineering companies that manufacture them." EMAG has designed the VL 2 to meet these requirements. "This vertical turning machine stands for automated, high precision production processes and low component costs in the manufacture of small chucked components," said the spokesperson.

The VL 2 vertical lathe is designed for the machining of small chucked components such as small gearwheels, planetary gears, sliding sleeves, pump components, synchronizer rings, chain gears or flange components with a maximum diameter of 100 mm and a length of up to 150 mm. The vertical pick-up lathe design is focused on providing a variety of manufacturing technologies for soft and hard machining and includes a complete automation system.

This comparatively small, space saving manufacturing solution also includes a number of details and high-tech components designed to provide fast processing:

  • The pick-up spindle ensures that the machine loads itself. It picks up the raw parts from the integral conveyor belt (which accommodates up to 24 workpieces) and later returns the finish machined component to it.
  • The 12-station tool turret is designed for short indexing times. It can also be equipped with driven tools in all 12 stations for drilling and milling operations.
  • All service units are quickly and freely accessible. The distance between operator and turret does not exceed 400 mm.
  • The machine base in polymer concrete MINERALIT is designed for stability as well as enhanced damping qualities, which provides improved surface finishes.

"We wanted to design a machine that guaranteed the highest possible degree of productivity in the manufacture of small components; and we have been very successful in that with our VL 2. Here too, size is of great importance. The machine's compact construction ensures that the chip-to-chip times are kept low," said Guido Hegener, Managing Director of EMAG Salach Maschinenfabrik GmbH. "Productivity levels of the VL 2 are approximately 15 percent higher than those of comparable automated horizontal turning machines."

"When talking about component quality one needs to consider another central and typical EMAG design factor besides the sturdy machine base: the alignment of all process-related components inside the machine," said the spokesperson. Workspindle and workpiece are located above the tools, preventing the formation of clusters and allowing for better flow of chips. The automation equipment is compiled to suit user requirements.

"The VL 2 is designed for flexibility," said Hegener. "The technology - from automation to interfaces and control system - can be chosen to suit on-site conditions." It is, for instance, possible to include an optional Y-axis or measuring probe. Where, on the basic machine, the workspindle is mounted on a compound slide that moves in X and Z, the VL 2 can also be equipped with an optional Y-axis in the turret. This allows for the efficient machining of highly complex geometries.

Capabilities of the VL 2 include:

  • Workpiece diameter: 100 mm
  • Chuck diameter: 160 mm
  • Travel in X: 700 mm
  • Travel in Z: 400 mm
  • Travel in Y (optional): ± 50 mm
  • Turret tool stations (turning tools / driven tools): Qty 12.

For more information contact:

Kirk Stewart

EMAG L.L.C.

38800 Grand River Ave.

Farmington Hills, MI 48335

248-966-4703

kstewart@emag.com

www.emag.com

Southwest

 

AR

David Fitzgerald

EMAG L.L.C.

Charlotte, NC

248-595-1117

dfitzgerald@emag.com

www.emag.com

NM

Kirk Stewart

EMAG L.L.C.

38800 Grand River Ave.

Farmington Hills, MI 48335

248-996-4703

kstewart@emag.com

www.emag.com

LA, OK, TX

Ric Lorilla

EMAG L.L.C.

Houston, TX

248-595-1530

rlorilla@emag.com

www.emag.com

Southeast

 

AL, FL, GA, MS, NC, SC, TN, VA

David Fitzgerald

EMAG L.L.C.

Charlotte, NC

248-595-1117

dfitzgerald@emag.com

www.emag.com

Northeast

 

NY, PA

James Petiprin

EMAG L.L.C.

38800 Grand River Ave.

Farmington Hills, MI 48335

248-910-8413

jpetiprin@emag.com

www.emag.com

CT, DE, MA, MD, ME, NH, NJ, RI, VT

Kirk Stewart

EMAG L.L.C.

38800 Grand River Ave.

Farmington Hills, MI 48335

248-996-4703

kstewart@emag.com

www.emag.com

WV

David Fitzgerald

EMAG L.L.C.

Charlotte, NC

248-595-1117

dfitzgerald@emag.com

www.emag.com

 

 

Midwest

 

MI, OH

James Petiprin

EMAG L.L.C.

38800 Grand River Ave.

Farmington Hills, MI 48335

248-910-8413

jpetiprin@emag.com

www.emag.com

IL, IN, WI

Tod Petrik

EMAG L.L.C.

Chicago, IL

248-470-2646

tpetrik@emag.com

www.emag.com

IA, KS, MN, MO, NE, ND, SD

Bill Konetski

EMAG L.L.C.

Minneapolis, MN

612-804-0857

bkonetski@emag.com

www.emag.com

KY

David Fitzgerald

EMAG L.L.C.

Charlotte, NC

248-595-1117

dfitzgerald@emag.com

www.emag.com

West

AZ, CA, CO, ID, MT, NV, OR, UT, WA, WY

Kirk Stewart

EMAG L.L.C.

38800 Grand River Ave.

Farmington Hills, MI 48335

248-996-4703

kstewart@emag.com

www.emag.com

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