Save up to 50% manufacturing cost with EMAG ECM Precision Machining

There's huge pressure for cost reduction ideas on precision parts machining. Here is an innovative solution which can deliver significant savings: EMAG ECM and PECM.

As it is a contactless procedure with no heat input, the process is not subject to any of the disadvantages experienced with conventional machining methods, e.g. tool wear, mechanical stresses, micro-fissures caused by heat transfer, surface oxidation or the need for subsequent deburring operations. All electro-chemical machining processes are characterised by stress-free stock removal, gentle transitions and smooth surfaces without burr formation.

Just imagine drilling 5, 10 or 20 burr free holes into your precision workpiece at the same time – without consumable costs for cutting tools and without the requirement for manual debarring!

Check out the ECM / PECM video to get an idea about the ECM Drilling process and contact us today with your application and machining requirements to get more information about this exciting new technology.

VL 2 P – THE IDLE TIME KILLER

The EMAG VL 2 P redefines the production formula: Compact design + Short distances + Highly dynamic axes = Short idle times. Shorter idle times lead to more workpieces machined which benefits you!

The VL 2 P is a two-spindle vertical turning machine with pendulum technology for parts that have a diameter of up to 100 mm. The main focus of the design of the VL 2 P was reducing idle times.

Result: Non-productive times due to loading and unloading have been almost completely eliminated.

The machine is ideal for workpieces with short machining times since the ratio of machining time to idle time is vital for the economy of the process.

EMAG Skiving Technology

The skiving method developed by EMAG offers new opportunities in the machining of precision components. The process is very fast and impresses with outstanding surface finishes that show no score marks. Surfaces that have hitherto been ground can now be skived. However, to use the process economically requires an insight into not only its technological advantages but also its performance limits.

The skiving process is totally different to conventional turning work, as the skiving tool carries out a rolling motion, whereby the cutting edge of an inclined CBN wheel moves over the rotating workpiece and the cutting speed is generated by the workpiece rotation. With the movements of tool and workpiece overlaid, the contact point of the cutting edge continuously moves along the component surface. This is ideal for the cutting edge; but the load bearing influences are very different to those experienced with conventional turning operations, with the influence of passive forces being noticeably greater.
The skiving process is a very fast one – about 5 to 6 times faster than that of previously known hard turning processes and 2 to 3 times that of grinding, resulting in exceptional surface finishes without any trace of scoring. Ergo, surfaces that hitherto had to be ground can in future be skived.

Best-in-class solutions for Automotive High Volume Manufacturing

Classic 'Nagare' – vs. World Class Manufacturing Strategy

Thailand will double vehicle production over the next 2-3 years from 2 to 4 Million units. 

New strategies are required to answer the challenges….quality, process capability, automation.

Check out the article in Asia Metalworking to get the scoop on EMG World Class Manufacturing.

Jump

Take a jump in 2012 from 'Classic Manufacturing' to 'World Class Manufacturing'. We will be publishing the reasons & metrics here on this blog.

EMAG Technologies

EMAG offers integrated manufacturing solutions for World Class Automotive manufacturing. Find out more at our seminar during METALEX 2011 21 December 2011.

EMAG Laser Welding

EMAG presents: highly efficient laser welding systems for transmission components and other rotation symmetric workpieces. This includes – besides transmission components in hardened steels – more complex components, such as differential casings in SG iron, which are to be mated with finish machined gears.

Laser Welding of Differential Carrier on EMAG ELC 250 DUO