Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Increasing demands made on precision and the push for the decrease of price of modern components is pushing traditional manufacturing processes to their limits. From September 10th-15th, 2012 at IMTS in Chicago, IL, EMAG will present three production technologies that complement or replace traditional processes such as turning, milling and grinding.
The ECM process is used to deburr components only at the points where material needs to be removed, and without it having any mechanical or thermal impact on the workpiece.
PECM for nickel- and titanium-based alloys
With its PECM technology (Precision Electro-Chemical Machining) EMAG presents a production process that opens up completely new fields of application. PECM is a process for the machining of high-alloyed materials, such as nickel- and titanium-based alloys. The disadvantages of traditional metal cutting – tool wear, mechanical stresses, micro-fissuring caused by heat, oxidization layering and the need for subsequent deburring operations – are eliminated, because this process is a non-contact one without heat input. All electro-chemical machining processes are characterized by stress-free material removal, smooth transition points and surfaces without ridge formations.
Six in one – the EMAG ECM deburring process can be adjusted to suit individual production requirements.
The advantages that the PECM process provides for different branches of industry are best shown with the example of a turbocharger for the automotive industry. The electro-chemical process is one that can be used to effectively in the machining of many high-alloy components, especially those in the high-temperature sector of the turbocharger – it also offers a much shorter and very efficient process chain. The typical clean-up operations necessary when traditional machining processes are used – such as deburring after milling – are no longer necessary. PECM machining operations are burr-free. And there is hardly any tool wear. The result: downtimes are minimal, when compared to milling (which requires regular tool changes). The process as a whole is sturdier and less prone to errors. And another important factor that our example of the turbocharger shows: the superb surface finish of the PECM process, where Rz-values of 0.3 micron can be achieved.
Will camshafts ever again be made of a single piece?
Heat-shrink assembly of camshafts for small-power and passenger car engines.
Another highlight is EMAG‘s heat-shrink assembly technology, a process that scores particularly well in camshaft production. The high degree of precision achieved with the joining process drastically reduces the number of cam profile grinding operations or – with the use of precision cams – avoids them altogether. Another benefit of the process is the ability to combine different materials in the construction of the shaft, such as forged cams (e.g. in 100Cr6) and sintered cams, which do not require regrinding. Accessory components, such as plugs and end pieces, can – like the shaft itself – also be made of better materials. This allows for the camshaft to be adapted to the requirements of the engine and to be optimized in load bearing capacity and manufacturing costs.
Operating costs are cut in half with the fiber laser on the new ELC 160 laser welding machine.
Operating costs reduced by 50 %
Production laser welding is already a highly productive process in the manufacturing of gearwheels. The use of diode-pumped solid-state lasers – such as disc or fiber lasers –reduces operating costs by up to 50%. EMAG has been involved with the use of solid-state lasers in the welding of powertrain components from an early stage and is considered a pioneer in the technology. EMAG again has fulfilled a promise to their users offering them the lowest possible cost-per-piece, by coming up with an innovative technology that brings true cost benefits.
For many applications, solid-state lasers allow welding without shielding gas. This not only reduces operating costs, it also avoids having to follow the annoying logistics imposed by the use of shielding and laser operating gasses. In many cases, the welding process can also be sped up considerably. This increases productivity and – through a reduction in energy input per unit length – reduces welding distortion, resulting in better component quality.
For more information:
EMAG LLC
38800 Grand River Avenue
Farmington Hills, MI 48335
Tel: (248) 875-0313
Fax: (248) 477-7784
E-mail: info@usa.emag.com
Web: www.emag.com
Attention: Peter Loetzner
Continue readingHigh component quality with low production costs is required in many applications involving machining chucked parts. At IMTS, September 10 – 15, 2012 in Chicago, EMAG will be showing these solutions which combine these requirements. One of the highlights at the show will be the introduction of the brand new VL 2 P, a vertical pick-up turning machine which operates using pendulum technology.
Whether you want to manufacture small chuck parts or larger components, the machining processes must ensure accurate component geometry while also guaranteeing low component costs. These requirements and more are met with the VL 2 P and VL 5i vertical turning machines as well as the VSC 400 DDS turning and grinding center from EMAG. The advance in productivity is provided by the EMAG design of these machines with the integrated pick-up automation and a machine body made of polymer concrete as well as the vertical design which ensures perfect chip flow conditions.
VL 2 P: Swinging to success
Workpieces up to 100 mm in diameter can be machined in full on the innovative VL 2 P, a two-spindle turning machine. The machine has two spindles because while one workpiece is being machined, the second spindle automatically loads itself using the pick-up method. This means that the next raw part is immediately ready for machining, resulting in extremely short chip-to-chip times. The focus during the design of this machine was efficiency and eliminating idle times. The VL 2 P also has an incredibly small footprint due to its compact design, which helps decrease the chip-to-chip times. See it in action at IMTS 2012 HERE.
VL 5i: Short idle times, perfect automation
The VL 5i turning machine is a universal solution for production companies. It can completely machine workpieces of up to 250 mm in diameter in a single clamping operation. In addition to the powerful pick-up working spindle with a rating of 28 kW and a torque of 300 Nm, the machine also has an automation system with a revolving belt which contains drag frames. The machine could be described as being self-automated, which means that new raw parts can be positioned and finished parts removed at any time. Another strength of the VL 5i is its short idle times because the distance between the loading and the machining positions is just 550 mm.
VSC 400 DDS: Grinding and turning combined
The VSC 400 DDS vertical grinding and turning center combines a range of processes and guarantees extremely cost-effective processes in the production of complex chuck parts with a diameter of up to 400 mm. Within a single clamping operation, the center can complete scroll-free turning and hard turning as well as subsequent grinding processes. Grinding is only used where quality and process reliability demands it. The center can also be fitted with drilling tools or hardening modules to suit the required machining task. Even measuring tasks can be integrated.
For more information:
EMAG LLC
38800 Grand River Avenue
Farmington Hills, MI 48335
Tel: (248) 875-0313
Fax: (248) 477-7784
E-mail: info@usa.emag.com
Web: www.emag.com
Attention: Peter Loetzner
Fryer Easy Turn Combination Lathe with Siemens SINUMERIK 840D sl CNC lets operators at Continental Machine program, set-up and run faster; critical for one-off operations
By definition, says Josh Johnson, vice-president, Continental Machine, Rockford, Illinois, his prototype and short-run production shop must constantly run lean. There can be no tolerating excessive programming, set-up or machining time of any kind, otherwise the shop loses and, in this economy, Johnson notes, that is simply unacceptable.
Continental Machine is a seven-person, 13,000 square-foot facility that houses a variety of CNC milling, turning, wire EDM, hole popping and grinding machines, as well as various sheetmetal and plastic injection molding machinery. Therefore, the shop is well positioned to produce a wide variety of metal and plastic prototypes used by its diverse customer base, which spans markets such as window hardware, bicycle components, automotive parts, chemical processing, medical devices and foodservice equipment. Materials processed here are just as wide-ranging, including aluminum, CRS, tool steels such as A2 and D2, zinc, brass, copper, bronze, titanium and a variety of engineered plastics such as glass-filled Delrin.
Recently, this job shop purchased a Fryer Easy Turn-21 CNC Combination Lathe, controlled by a Siemens SINUMERIK 840D sl numerical control. The two operators responsible for this machine upgrade at Continental had limited experience with CNC and none whatsoever with the Siemens protocol, as this was the first of its kind at the shop.
The Easy Turn-21 was particularly appealing to Josh Johnson, who comments, “The set-up is extremely easy. Teaching the tools, altering the lengths and diameters is kept very simple. After the initial learning curve, which took only a few days, the operators picked up on the conversational programming, right away. Also, one of the best features on the machine was that you could still turn the parts by using the electronic handwheel and just one function, such as hogging off material automatically or putting on a tapered thread.” He noted this feature was not only more comfortable for the operators, but it also allowed them to quickly and efficiently prove out part programs. Johnson commented that this would not have been possible on previous machines, owing to the flexibility of the control onboard the Fryer. The result has been a minimum 20% improvement in the overall cycle time on most part programs run at Continental. For this primarily prototype job shop, that fact translates into a substantial increase in the work product possible here.
Echoing this sentiment, Sue Ostrander, sales manager, Fryer Machine Systems, explained the process that led her company to select the SINUMERIK 840D sl numerical control for all its milling and turning machines, a move that was recently formalized by the company and announced to the trade.
“Since its inception 26 years ago, family-owned Fryer Machine Systems has based its operation on three core principles: build a quality product, price it fairly and provide quality service. This philosophy has allowed Fryer’s business to grow even in challenging times,” she said.
Fryer manufactures a diverse line of over 50 models of high-quality CNC machine tools in its 50,000 square-foot facility in Patterson, New York. Over the years, Fryer has become well-respected for its quality and innovation, throughout the job shop and production machining market segments.
“Moving to the Siemens 840D sl platform was the next step in Fryer’s ongoing commitment to provide our customers with the most innovative machine tools available in the market today,” Ostrander continued. “The Siemens solution allows machine tool end-users to achieve higher productivity through easy and intuitive features and step-by-step, on-screen programming. This enables them to dramatically reduce set-up, programming, and tooling times, while significantly increasing output.”
“The SINUMERIK 840D sl modular design allows us to take full advantage of the superior mechanical features in our machines,” continued Larry Fryer, president and CEO, Fryer Machine Systems. “Fryer has always been known for our easy conversational controls and the move to Siemens has allowed us to greatly enhance this feature,” Fryer noted. “The 840D sl menu-driven system combines an advanced geometry calculator that displays the part while the operator is programming it. Sophisticated solid model graphics allow the operator to verify the part program with more clarity than ever before,” he said.
Larry Fryer has also been impressed with the automatic tool set-up and easy part set-up, made possible by the Siemens CNC. Fryer explained that auto-run mode is where many operators experience difficulty. Siemens and Fryer Machine Systems worked together to create an electronic handwheel run mode that gives the operator a safer way to prove out program execution, both forward and backward, using a standard electronic handwheel.
Fryer further stated, “Siemens provides us with a highly flexible solution that is critical to our ability to meet the specific needs of each customer. Our enhanced capability to offer the same control for both turning and milling gives Fryer machines a unified platform that is very important to customers both in the short-term and for long range expansion. Coupled with Siemens quality and reliability, they are invaluable to us in competing in today’s aggressive marketplace.”
Johnson added this comment on the service and training received by his operators at Continental. “Siemens has been helpful and very thorough in their training and after-sale service. The ShopTurn program, being integral to the control, now enables us to accurately determine tool path, potential collisions, tool changes and real world run time. This makes our operators’ jobs much easier, with the added benefit of allowing us to estimate much more accurately than ever.” Johnson further noted the CNC has substantial hard drive space, thus allowing most programs to be stored directly on the machine, though the company does maintain a back-up system.
For more information on this story, please contact:
CONTINENTAL MACHINE CO.
Email: conmach@onecommail.com
FRYER MACHINE SYSTEMS, INC.
Web: www.fryermachine.com
SIEMENS MACHINE TOOL BUSINESS
John Meyer
Manager, Marketing Communications
Siemens Industry, Inc.
(847) 640-1595
www.usa.siemens.com/cnc
SiemensMTBUMarCom.industry@siemens.com
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.
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