The blank is a forged steel component.
Four VL 8s from EMAG carry out the rough-machining processes on the component.
Work area of the VL 8 at Bharat Forge Daun
The circulation belt of the VL machines also serves as a parts store.
Complex components in the micrometer range characterize the work in Daun.
Unusually sophisticated components and high-strength materials for high-tech applications, like stator housings for electromobility with ensured quality in the range of microns, are among the machining challenges tackled by the specialists at Bharat Forge Daun. Right in the middle of it all are several vertical turning machines from EMAG, which are in operation around the clock, five days a week. With production demands like these, it is obvious that service from EMAG is particularly important. But what exactly was the deciding factor in the decision to invest in these machines?
Complexity is something of a hobbyhorse at Bharat Forge Daun. The company, based in Germany, produces rotationally symmetrical series components as a contract manufacture, as well as tools and molds, which are then used by the forging experts at Bharat Forge CDP and Bharat Forge Aluminiumtechnik. This means that challenges like difficult surfaces and positional arrangements are common.
"Extreme accuracy requirements in the micrometer range are always part of our work," said Christoph Steffens, Head of Mechanical Engineering at Bharat Forge Daun, summarizing the initial situation. "In this context, we monitor the processes very comprehensively, carry out many measurements and even accompany the component development on request so that the production of the component runs efficiently. We offer this expertise on the market for sectors such as the automotive industry, general mechanical engineering and the production of agricultural machinery."
Efficient Machining of Forged Stator Housings
A stator housing used in the hybrid drive of a large German automotive company shows what this means. Even at first glance, it is clear that its pot-like shape and various geometric details are sophisticated. What is more, the blank is a forged steel component-a rarity in this field of application. Its material properties are an additional challenge for the southwest German machining experts. In addition, the client has continuously increased the required quantities over the years (and will continue to do so). So how do you combine accuracy, efficiency and process reliability in this environment? Bharat Forge Daun's answer has a lot to do with EMAG's mechanical engineering components, as the specialists have been relying on EMAG lathes for some time.
Vertical Design with Decisive Advantages
The vertical design of these solutions played an important role in the investment decision. The horizontal machine from another manufacturer had caused some difficulties in the past. For example, annoying chip clusters regularly formed, which had to be removed manually two to three times per shift.
"It was therefore obvious to us that we should carry out these processes in machines with a vertical design, because their unhindered chip flow prevents many disruptions. Our objective was to achieve maximum process reliability," said Steffens. The decision in favor of EMAG was also based on existing knowledge: the machine manufacturers used examples from other customers to show how stator machining is carried out in their machines-with low nonproductive times and high-precision handling processes. Integrated automation, including a pick-up spindle and lateral conveyor belt, offers fast processes, while the stable base body made of the polymer concrete Mineralit stands for quality in turning and milling processes.
EMAG Service in Focus
Last but not least, the response time and the expertise of EMAG's service department play an important role for Bharat Forge Daun. A regional service technician is always on site within a few hours and solves any problems directly.
"The machines are very robust. Nevertheless, this issue is important because we produce five days a week in three-shift operation, and so far, we have always been helped with minor faults in record time-for example with a defective light barrier. The repair has never taken longer than two hours," said Steffens, who also reports that EMAG has already been on site via remote service.
For more information contact:
EMAG L.L.C.
38800 Grand River Ave.
Farmington Hills, MI 48335
248-447-7440
info@usa.emag.com
www.emag.com