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The CI machine from EMAG ECM: A highly effective solution for deburring complex components

Autonomous steering and brake systems, hydro-pneumatic chassis, or radically improved gas mileage – these buzzwords represent a technological change that is triggering a domino effect in the automotive and other industries. An increasing number of components have to satisfy extremely demanding quality requirements. They need to leave the production process in perfect condition and without any defects. If not, the autonomous brake system of a car might fail in crucial moments, for example. This is where deburring plays a crucial role. The required degree of perfection is ensured by a process called electrochemical machining (ECM). Currently, many planners are looking for lean production systems to supersede traditional deburring processes. With this in mind, developers at EMAG ECM have thoroughly revised their CI series of machines: The new ECM CI machine ensures extremely fast and perfect electrochemical processes for deburring and machining (“ECM cleaning”). It also requires only minimum installation space. Even complex parts such as pumps or hydraulic housings can be deburred quickly, without error, and in a reproducible manner using the EMAG’s ECM technology. And: With the new CI machine, users also benefit from excellent value for money.

 

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rollFEED® Turning on EMAG machines: Advancing the speed of turning operations

The technological and business competition in the automotive industry is a driver of change in production technology. Even classic processes like turning are under revision. For this reason, the geometries of many components are becoming more complex, and the requirements on surface quality are rising. At the same time, manufacturing costs need to become lower and lower. Which processes are suitable for achieving these goals? The rollFEED® Turning process (patent pending) by the German toolmakers at Vandurit is providing an unusual answer to this question. The process can be used exclusively with all EMAG vertical turning centers with chuck diameters up to 500 mm. It expands turning processes by a third axis, and it can be retrofitted. rollFEED® Turning offers radically shortened cycle times, lower tool costs, and better surface quality even with greater cutting depths. Even complex part geometries can be created in a single motion with just one tool. Customers benefit from a significant leap in performance for the turning of demanding components.

 

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EMAG at the EMO: Focusing on electric drive systems and the “smart factory”

Electromobility and Industry 4.0 – these industrial megatrends are featured prominently in the EMAG Group booth at the EMO in Hanover from September 18 to 23 this year. Throughout the show, EMAG machine manufacturers will demonstrate their role as “facilitators” of technological change. For example, they have complete solutions available for the efficient production of central 10 components of electric drive systems. Exhibition visitors will see several high-performance machines in operation – including world-firsts in the areas of turning operation, laser welding/joining and gear cutting. At the same time, the EMAG Group is also accelerating the digitalization of its production technology to establish intelligent factories. Therefore, the EMO will have a dedicated area where customers can test essential Industry 4.0 solutions. A main focus is the consistent usability of the software, which will continue to simplify the control, monitoring and analysis of production.

 

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EMAG acquires RICHARDON's gear technology

On May 1st, EMAG acquired the entire gear cutting business and related name rights from Richardon. This step further enhances the application expertise of the EMAG Group. Richardon is a leader in large-module gear production using gear hobbing and skiving processes. The acquisition perfectly complements existing technologies in the EMAG Group.

 

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VLC 200 GT from EMAG: New Custom-Fit Turning and Grinding Solution for the Machining of Automotive Gears

The production of a large volume of parts with extremely high quality has been a key feature in the production of automotive transmissions for decades. Developments in both the marketplace and technology, however, are continuing to change production at a very fast pace. For example, the number of gears needed for the production of our cars has been rising. This increase in quantity is pushing the production volume of gears even higher. At the same time, the competition from new market participants in Asia is intensifying. What can the transmission builders of OEMs and suppliers do in their production areas to address these developments? One of the most efficient answers to that question is a solution from EMAG Maschinenfabrik. The EMAG Groups VLC series offers customers multifunctional machines that perform an array of hard machining processes on the transmission components in quick succession. The company, which is based in Salach, Germany, and specializes in turning and grinding, has now added another important element to this portfolio, the new VLC 200 GT. This machine was developed by EMAG engineers especially for the chuck machining of automotive gears. Users benefit from not only highly efficient turning and grinding processes in a single clamping operation, but also by receiving excellent value for their money.

 

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Modular System for Line Production: the VL Series from EMAG

Vertical production machines are EMAG's territory. It all began with the VSC series, which laid the foundation for the successful machine concept of the vertical pick-up turning center. This machine concept runs through nearly the entire product range of the manufacturer, and it takes on its latest form in the VL series.

 

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Multi-process module by EMAG ECM: Electro-chemical efficiency lifts automotive mass production to a new level

The idea behind the “platform strategy” in automotive production is as simple as it is effective: The manufacturers no longer construct completely unique engines, transmissions, and components for every model, but instead use numerous “common components” for similar vehicles. This results in a massive increase in unit volumes, and a decrease in the development and unit costs. However, the consequent boom in production requires an answer to the question of what technologies can possibly manage the growing unit volumes efficiently—especially when many of those components need to be machined with ever greater precision then previously required. It was exactly this situation that led EMAG ECM to develop a new machine concept that unites innovative electro-chemical machining (ECM) with the demands of the fast-paced mass production of automotive components. The new ECM machine with the multi-process module (MPM) has already been successfully implemented into operation with an automotive supplier, where it produces high-quality injectors for car engines by the second.

 

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High performance for the welding of gears

In every synchromesh or dual-clutch transmission, there are gears with a synchronizer mechanism:  They transmit the torque of the engine to the drive axle via a coupling body (synchro body) and a shift sleeve.  There is one gear for each step of the transmission, meaning that a seven-gear transmission requires 7 + 1 gears. A design that has proven successful is that of a wheel and synchro body, with the two separate parts joined and welded together.

 

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HLC 150 H by EMAG KOEPFER: All-round gear-cutting solution for more flexibility and lower cost

More than ever, planners in the automotive industry are faced with the crucial challenge of flexibility in production technology. Manufacturers continually need to cope with modified ranges of components. For instance, the geometry can change very quickly. For gear cutting in particular, this development can reach new extremes. Take the example of steering components: Production planners are looking for extremely flexible machines that can efficiently cut the gears of steering pinions, worm gears and screws. This is how an EPS steering gear can be produced on a single machine. Innovative machine builders are able to accomplish this task, as demonstrated by EMAG KOEPFER with their horizontal gear cutting machine HLC 150 H – an all-round solution in every way. This high-performance machine is able to process a very wide range of workpieces – transmission and anchor shafts, pinions, and planetary gears with a length of up to 500 millimeters. It features all relevant gear cutting technologies such as gear hobbing, skiving, screw milling, worm skiving and chamfering. Workpieces up to module 3 can be finished without burrs, meeting high quality requirements. You could hardly ask for more flexibility in gear production.   

 

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Markus Isgro

Press and Communication

Phone: +49 7162 17-4658
Fax: +49 7162 17-4027
E-Mail: communications@emag.com
 

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