With the EMAG VTC 315 DS for shaft machining it is possible to choose the technology that best suits manufacturer's applications. Dr. Guido Hegener, the executive responsible for grinding technology at EMAG Salach Maschinenfabrik GmbH, comments on the diverse applications: "We are consistently following the path of combination machining. As a rule, our customers manufacture different workpieces on the machine. We intend to offer them the best technology for every application."
The VTC 315 DS is designed for the manufacture of medium and large batches of high-quality components such as gear shafts, rotor shafts, pump shafts, motor shafts or cardan shafts. The machining technology is chosen accordingly. Sturdy workpieces are machined using the scroll-free turning technology. The grinding technology is preferred for smaller, less stable components. "This makes us more flexible and allows us to choose the right technology for every individual requirement," said Dr. Hegener.
The machine can be used as a full-fledged grinding machine, or a full-fledged turning machine, or a combination of both. "When choosing a technology one should take a closer look at the cycle time and, in particular, at the tooling cost. Unit production costs are usually higher with hard turning and scroll-free turning than with grinding, although CBN grinding wheels are rather expensive. It is for this very reason that the user has to decide which manufacturing technology to use," said a company spokesperson.
Different technology modules are available for different workpieces. The developers of the VTC were also considering the machine as an investment in the future. Should production requirements change, the machine can be equipped - at very little expense and effort - with different technology modules that make it suitable for machining of the new workpiece. At present, the technology modules available are:
- Soft turning
- Milling (side-and-face mill)
- Drilling
- Gear hobbing
- Hard turning
- Scroll-free turning
- Grinding / simultaneous grinding
- Out-of-round grinding.
The VTC 315 DS is suited for complex manufacturing processes. Whether the job includes the high metal removal rates of turning and milling or the gentler grinding process - the VTC series of machines offers the possibility to integrate most of the metal cutting processes. This allows for the creation of complete VTC production lines for soft and hard machining. Turning, milling, drilling, grinding and gear hobbing have already been modularized for this particular machine platform. It provides the VTC with an extensive field of application. "We have already installed complete production lines of VTC machines for the soft machining of crankshafts. Almost all of the operations could be accommodated on machines from the VTC series," said Markus Woitsch, Chief of the Production Team for shaft machines, concerning the production line concept of the VTC. "Naturally, subjects like spare parts stock and unified machine operation also play a decisive role in the eye of the customer. With a production line that interlinks a number of different VTC machines and utilizes different manufacturing technologies, spare parts stock can be drastically reduced, as 80% of the VTC machine components are the same. Only the technology modules change, when a VTC is adapted for a new machining requirement."
The VTC 315 DS accommodates turning as well as grinding technologies. For example, the turret carries out all turning operations, while the second station is used for the grinding work. This way, shafts can be complete-machined: the cylindrical bearing seats, the shoulders and the grooves - all machined in a single set-up. "Clamping errors play a particularly important part when it comes to high-performance components. Radial runout can be much reduced when a workpiece does not have to be re-clamped several times," said Dr. Hegener. "To keep downtimes caused by tool changes to a minimum, sister tooling is provided for all turning operations. And the tool life of grinding wheels is so high that the time taken up by a wheel change is of no consequence."
The VTC 315 DS is designed for sturdiness and rigidity with a machine base of Mineralit (polymer granite). EMAG reports that the damping properties of this material is eight times that of grey cast iron. The vertical design also aids unhindered chip flow. This is particularly important in soft machining, as it often involves volume-intensive chipping operations. The vertical construction means the machine has a smaller footprint.
Automation on the VC 315 DS lies in the turret. A gripper, housed in the turret, collects the raw-part from its storage section and transfers it to the clamping position. Once the workpiece is machined, it is transferred out of the machine the same way. The work spindle has 330 Nm constant torque, and the grinding spindle a power rating of 30 kW, for the capacity to perform heavy metal removal work on the machine. The control system used is a Siemens 840 D with EMAG grinding software that simplifies programming and operation.
For more information contact:
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