Turning and grinding: complete machining on a VLC 100 GT
With integrated O-automation for workpiece transport, the VLC 100 CT is loaded and unloaded using the pick-up principle. Also shown is the measuring probe.
Internal grinding of a bore on the VLC 100 GT
The integrated measuring probe is used to check the machining quality at programmed intervals.
Hard turning on the VLC 100 GT
"When it comes to machining times, combining various machining processes in one set-up offers cost- and time-saving potential," said an EMAG spokesperson. "With the combination of hard turning and grinding, only the geometries which require greater precision are ground after turning. For this requirement, EMAG developed the VLC 100 GT that efficiently combines vertical turning technology with finish grinding. For chucked components up to 100 mm in diameter, such as gears, single cams and cam rings, pump rings or sprockets, first-grade machining results are achieved in significantly reduced cycle times."
The first step is to pre- or complete-machine all those component surfaces that can be hard turned and then, without changing the set-up, finish grind all areas that require high-precision geometries. "This process has two advantages," said the spokesperson. "The turning process is considerably faster than grinding flat surfaces, and wear and tear on the grinding tools is vastly reduced with only finish grinding operations carried out. Since the workpiece is machined in a single set-up, the whole process is more efficient, without clamping errors, and less time-consuming than when carried out on two machines." The VLC 100 GT integrates combination machining into EMAG's pick-up concept, where the main spindle is used to load and unload workpieces from the integrated conveyor belt or shuttle. The machining area is designed to be easy to equip with a variety of turning and grinding modules. "This compact manufacturing system also includes integrated measuring, thus guaranteeing a top component quality at a reduced cost per part," said the spokesperson.
The flexible configurability of the VLC 100 GT covers a wide range of applications. For example, it can be used as a conventional vertical grinding center equipped with two grinding spindles for external and internal grinding, or for combination machining, with an additional block toolholder for hard turning operations. The VLC 100 GT can be equipped with corundum or modern CBN grinding technology, and vitrified-bonded CBN grinding wheels can be dressed using a rotating diamond roll. A structure-borne sound system serves as GAP-control between the dressing roll and grinding wheel. An adaptive process control system is designed to achieve short cycle times.
"All vertical pick-up machines from EMAG feature a machine base of MINERALIT polymer concrete that stands out for its damping effect, eight times greater than a cast iron base," said the spokesperson. "This vibration damping quality significantly contributes to the excellent surface finish of the components. Optimal machining quality is achieved with the integrated measuring probe, located between the machining area and pick-up station, where it is not only protected from debris, but it also allows the measuring process to take place in the same set-up, either directly before or after machining to save clamping time." The probe can also be used to take intermediate measurements.
According to the company, the quality of the VLC 100 GT is best shown by a concrete example such as the machining of sprockets, which displays the advantages of combination machining. Once the pick-up spindle has loaded the component, the integral internal grinding spindle carries out the first operation. Then the sprocket bore, with its small allowance, is finish ground with CBN. The two block toolholders also present in the machining area then machine the flat surfaces on the sprocket. "The hard turning technology used for this operation not only results in very short machining times, but it also ensures that no subsequent operations are necessary," said the spokesperson. "The measuring probe, located between the machining area and the loading station, now proofs the machining quality. The whole process takes under 50 seconds in one clamping operation, underlining the performance of this vertical turning/grinding center."
With the VLC 100 GT, EMAG has created a system for the combination machining of chucked components, designed for impressive performance despite compact construction. "Making use of the pick-up spindle to load the machine, plus the application of cutting-edge grinding technologies in combination with turning operations, provides a machine design focused on performance," said the spokesperson. Whether the VLC 100 GT is used in a production line for the manufacture of large quantities of components, or as a stand-alone, this vertical turning/grinding center offers a vast range of applications.
The VLC 100 GT offers the following features:
- Precision manufacture and finish machining of medium and large batches of chucked components at high output rates
- Complete machining in a single set-up, thus improving productivity
- Higher life expectancy for turning, grinding and dressing tools
- Only small amounts of grinding sludge are generated during combination machining, thus minimizing waste removal costs.
Technical data for the VLC 100 GT are as follows:
- Chuck diameter, max: 160 mm
- Machining diameter, max: 100 mm
- Main spindle: power rating at 40 / 100 % duty cycle: 19.5 / 12.5 kW
- Swing diameter: 210 mm
- Travel in Z: 375 mm
- Travel in X: 900 mm
- Main spindle max speed: 6,000 RPM
- Main spindle torque at 40 / 100 % duty cycle: 75 / 48 Nm
- Main spindle - front main spindle bearing, max diameter: 80 mm.
For more information contact:
Peter Loetzner
EMAG LLC
38800 Grand River Avenue
Farmington Hills, MI 48335
248-477-7440
info@usa.emag.com
www.emag.com
Southwest
AR
David Fitzgerald
EMAG LLC
248-595-1117
www.emag.com
TX, OK, LA
Ric Lorilla
EMAG LLC
248-595-1530
rlorilla@emag.com
Southeast
VA, NC, SC, GA, FL, TN, AL, MS
David Fitzgerald
EMAG LLC
248-595-1117
www.emag.com
Northeast
PA, NY
Kirk Stewart
EMAG LLC
248-996-4703
kstewart@emag.com
ME, NH, VT, MA, RI, CT, NJ, DE, MD
Jonathan Chomicz
EMAG LLC
248-497-8526
jchomicz@emag.com
WV
David Fitzgerald
EMAG LLC
248-595-1117
www.emag.com
Midwest
IN, MI, OH
Kirk Stewart
EMAG LLC
248-996-4703
kstewart@emag.com
ND, MN, WI, SD, NE, KS, IA, MO, IL
Tod Petrik
EMAG LLC
248-470-2646
tpetrik@emag.com
KY
David Fitzgerald
EMAG LLC
248-595-1117
www.emag.com
West
Peter Loetzner
248-477-7440
info@usa.emag.com
Arnie Sugiyama
Caltec International
19801 Hamilton Ave
Torrance, CA 90502
310-527-4110
arnie@caltecusa.com