At Gear Expo 2015, EMAG USA will feature manufacturing systems for precision metal components alongside the North American premier of its newest technology: induction hardening.
The new platform VT and VL Series for shafts and chucked components will be on display for visitors to experience the EMAG modular inverted vertical lathe design. With the goal to develop a system of modular machines geared for use in the manufacturing of medium and large batch runs, EMAG offers flexible solutions on a standard platform. Single spline hobbing, for example, will be displayed on a VT vertical lathe for shafts. With the capability of offering gear cutting on a standard machine, EMAG modular machines offer specialized and custom hobbing machines. Machining is carried out in four axes at a maximum speed of 6,000 RPM. The process employs two turrets with twelve tool stations each, equipped with turning tools or driven tools. One common feature of the two VT and all four VL machine sizes is the shared modular design. Their small footprint is designed to reduce floor space costs and increase flexibility in floor layout options.
Every VL and VT machine features an integrated O-automation system for transporting workpieces. When combined with the self-loading pick-up spindles, this automation concept ensures short cycle times and high productivity. To accommodate machine operators, all the service units are easily within reach, with the various units (electrics, hydraulics, cooling system, cooling lubricant and central lubrication system) accessible at any time so that the machines can be maintained with ease. While the standard lathes are commonly used for gear blanks, a wide range of technologies can be incorporated into the machines, including turning, grinding, hobbing, chamfering, induction hardening and laser welding.
The technologies in the EMAG Group cover the entire spectrum of metalworking, including non-traditional processes. The latest addition to this technology portfolio, eldec will display induction hardening systems with a modular induction (MIND) machine at the show. Featuring Simultaneous Dual Frequency (SDF) technology where two different frequencies are applied to the workpiece, MIND machines can apply mid-frequencies to penetrate deeper and heat the root of the gear tooth simultaneous to high frequencies to accurately heat the tip of the tooth. Eldec hardening systems complement the workpieces machined by EMAG lathes to create efficient, complete production lines. The machine concepts and complete systems from EMAG offer modular and customized solutions for the production of workpieces in nearly every industry. They will be at booth 1304.