EMAG LLC  

Farmington Hills,  MI 
United States
  • Booth: 1629

The EMAG Group covers the entire spectrum of machining processes in the metalworking industry. Active in the automotive, oil field, power generation, aerospace and large equipment industries, EMAG is a trendsetter in the field of vertical turning centers and multi-functional production machines. The leader in inverted vertical pick-up lathes, EMAG has integrated its pick-up principle into a wide array of technology-specific machines offering world-class manufacturing with a minimal footprint, short chip-to-chip times and unsurpassed quality. Our focus is on complete processes that allow the customer to machine everything in a single set-up.

EMAG Group Technologies
• Turning
• Milling
• Grinding
• Hobbing
• Laser Welding
• Electro-Chemical Machining
• Induction Hardening
• Heat Shrink Assembly

The German based company is an important partner in the realization of complete manufacturing lines world-wide with their North American representation located in Metro-Detroit.


 Press Releases

  • The vertical pick-up lathes in the VL series represent a new machine concept from the EMAG Group: modular machines. Based on the extremely successful vertical pick-up system invented by EMAG, over 20 years of experience in machine solutions was utilized to develop this new machine model to comprise one of the most flexible and most effective manufacturing systems currently on the market.

    Modular design reduces cost

    With the aim to develop a system of modular machines ideal for use in the manufacturing of medium and large batch runs, one common feature of all the new EMAG modular machines is the shared basic, compact design. Their small footprint means reduced floor space costs and flexibility in machine layout (for example, Chaku Chaku or closed loop arrangement). Every VL machine features an integrated O-automation system for transporting workpieces on its left-hand side. 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 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. With low maintenance costs due to the use of standardized components, excellent accessibility, reduced floor space costs from the compact design, integrated automation and short cycle/idle times reducing the cost per piece to a minimum, the goal of EMAG modular machines is clear: cost saving without quality compromise.

    The VL series vertical pick-up turning machines were specially developed for manufacturing precision chucked parts with machines available in 4 sizes to cover as wide a range of project sizes as possible. The smallest machine, the VL 2, is designed for chucked components up to 100 mm in diameter, with the VL 4, VL 6 and VL 8 machines increasing the size of the workpieces that can be handled by 100 mm each. With these options, the VL series covers a variety of workpieces and accommodates components up to 400 mm in diameter.  

    Each VL machine features a tool turret with up to twelve (driven) tools, which ensures short swiveling times and, therefore, falling cycle times for machining chucked parts. Furthermore, the lathes can be fitted with a Y-axis in the turret to allow for the machining of complex geometries to increase the possible fields of application for the VL product family.

    The entire machine concept is based on maximizing component quality. The machine body is made of vibration-absorbing MINERALIT® polymer concrete. Together with the self-loading, high performance spindle, which completely eliminates clamping errors, these design elements ensure perfected machining. The vertical layout creates ideal chip flow conditions as chips naturally fall down and out of the machining area, bringing an end to time loss due to operators clearing nests. Every VL machine can be fitted with an optional measuring station located outside between the machining area and the pick-up station, allowing for integrated quality control. Measurement thus becomes a cohesive part of the process during transportation to the loading/unloading station, thus optimizing time while ensuring quality.

    Modern manufacturing with VL machines

    EMAG’s VL series of vertical pick-up turning machines are the perfect tool for reacting to the increased demands of the global market. The modular machines combine the latest manufacturing technologies with a smart design to ensure maximum productivity from every EMAG VL product. Regardless of the workpiece, the VL 2, VL 4, VL 6 or VL 8 enables you to manufacture top-quality chucked components using world-class technology at minimum part costs. Thinking about modern machining? Think vertical!

  • (Aug 14, 2017)

    South-Tec 2017, Booth 1629: EMAG Presents World-Class Machining Quality with Modular Standard Series!

    At South-Tec 2017, October 24-26 at the TD Exposition Center in Greenville, SC, EMAG will feature manufacturing systems for precision metal components with the VL 2 modular vertical turning machine for the low-cost production of chucked components with a diameter of up to 100 mm.  

    This machine from the VL series will be on display for visitors to experience the successful EMAG modular inverted vertical lathe design. With the aim to develop a system of modular machines ideal for use in the manufacturing of medium and large batch runs, one common feature of all four machine sizes is the shared modular, compact design. Their small footprint means reduced floor space costs and flexibility in machine layout. Every VL machine features an integrated 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. (More information at vl-vt.emag.com)

    The technologies in the EMAG Group cover the entire spectrum of metalworking, including non-traditional processes. Electro-Chemical Machining (ECM) is used in the aerospace sector for the manufacture of blisks, while laser welding is essential in light weighting automotive components. eldec modular induction (MIND) hardening systems are also available from EMAG. Featuring Simultaneous Dual Frequency (SDF) technology, eldec hardening systems compliment the workpieces machined by EMAG lathes to create efficient, complete production lines. The flexible machine concepts and complete systems from EMAG offer modular and customized solutions for the production of workpieces in nearly every industry. We look forward to welcoming you to booth 1629!

    About EMAG:

    The EMAG Group covers the entire spectrum of machining processes in the metalworking industry. Whether for chucked components or shafts, the companies under the EMAG umbrella offer the latest technological advances to optimize a manufacturing solution for every customer’s requirement. EMAG is a trendsetter in the field of vertical turning and multi-functional production machines with a variety of technology centers allowing EMAG to become an important partner in the realization of manufacturing solutions for the production of transmission, engine and chassis workpieces, as well as for OCTG components and coupling threads of the oil field industry and exotic materials used in the aerospace industry. The leader in inverted vertical pick-up lathes, EMAG has integrated its pick-up principle into a wide array of technology-specific machines offering world-class manufacturing with a minimal footprint, short chip-to-chip times and top quality. Our focus is on complete processes that allow the customer to machine everything in a single set-up.

    EMAG Group Technologies

    • Turning
    • Milling
    • Grinding
    • Hobbing
    • Laser Welding
    • Electro-Chemical Machining
    • Induction Hardening
    • Heat Shrink Assembly

    The German based company is an important partner in the realization of complete manufacturing lines world-wide with offices around the globe. Their US representation is located in Metro-Detroit.

  • 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. The EMAG ELC 160 HP is a manufacturing system from EMAG specially designed for this operation of joining the wheel and the coupling body together. In a production line, the ELC 160 HP handles the sub-operations of joining (pressing), pre-heating for welding (if required), and finally laser welding. To achieve the quickest possible cycle times, these sub-processes run in parallel. The ELC 160 HP is a rotary transfer machine, making it perfect for high-productivity manufacturing. This also explains its name: the abbreviation “HP” stands for “high performance” or “highly productive.” With this machine, typical gears for car transmissions are produced in about 10 seconds (!). There is nothing new about the principle of a rotary transfer machine. On the contrary, in many areas rotary transfer machines have been deemed too inflexible and have been superseded by other machine designs. This is where the real innovation of the ELC 160 HP comes into its own: a method of automated retooling for workpiece clamping, patented by EMAG, allows the ELC 160 HP to manufacture a variety of workpieces very flexibly, down to a batch size of one. Four processes simultaneously—high performance thanks to smart indexing The machine structure is centralized, in the truest sense of the word, around a central column on which all the components are mounted. A rotary indexing table arranged around this column provides for the transport of parts to the four process stations. A series of special design features ensures that the workpiece is positioned accurately in the machining station despite the high speed of the rotary indexing table. The high machine accuracy of the ELC 160 HP, in combination with EMAG's clamping technology, makes it perfect for even the most demanding, extremely narrow welds. The machining process begins at the loading/unloading station. Two pick & place units, equipped with pneumatic grippers, transport the parts from the conveyor belt to the rotary indexing table and back. From there the parts proceed to the joining station. This station can be equipped with up to three (different) joining punches, selected by NC commands and set up with no loss of time. This provides full flexibility and retooling freedom for applications such as manufacturing an entire set of gears for one transmission. The joining operation itself is performed quickly and precisely by a servo press, with an integrated force/stroke monitor for process monitoring. In the next step of the cycle, the workpiece reaches the third machining station, where it undergoes induction pre-heating. Here too, the user can make use of a slide unit with up to two inductors, which likewise permits automatic retooling. One brief turn of the indexing table later, the workpiece reaches the core of the machine, the laser welding station. Here too there is something special: EMAG clamps the workpieces axially for welding, both to prevent distortion and to protect the workpiece from spatter. This clamp and fixture system can be reset automatically for different workpiece geometries, in time with the cycle of the machine. Up to three fixtures can be made available, which is usually enough. So maximum flexibility and retooling freedom is provided here as well. This principle of automated retooling (an EMAG patent) maximizes the efficiency of the ELC 160 HP, as it avoids not only a manual retooling procedure, but also the time spent waiting for the destructive testing of the first workpiece welded, which is required after manual retooling. By performing the sub-operations of loading/unloading, joining, pre-heating, and laser welding in parallel, the ELC 160 HP attains maximum productivity: Gears for car transmissions are usually produced in a cycle time of just 10 sec. The automated retooling manages to square the circle by eliminating the disadvantage of rotary transfer machines, namely their low flexibility. Like the two stations before it, this station is also equipped with a slide unit with up to three counter bearings, in order to ensure automatic retooling here as well. The weld head is equipped with an X-axis for the seam position and a Z-axis for adjusting the focal position. As an option, this station can also be equipped with a crosshair camera. All four processes described above run in parallel, allowing for extremely quick cycles with a record time of just ten seconds. Compact structure—perfect ergonomics No compromises had to be made in ergonomics or accessibility for maintenance, despite the complex structure of the machine. With the process stations arranged at a 90° angle, the machining areas are all separate and therefore easily accessible. It is theoretically possible to perform maintenance on all four machining areas at the same time without difficulty. All of the technology required for operation of the system is housed in a control cabinet next to the machine unit, compact yet easily accessible. This gives access to all the electrical and pneumatic systems, as well as the induction generator, sensors, welding fume extraction and filtering, and CO2 extinguisher, all in one central location. The fixed beam guide and welding optics are also significant for maintenance tasks. These ensure not only extreme operational reliability, but also highly user-friendly setting and maintenance work. In addition, the fixed welding optics ensures that the laser always points into the interior of the machine, for extra safety in the workplace. The user therefore benefits from a machine layout which is both ergonomic and very safe. Laser technology—solid-state lasers only The ELC 160 HP uses only solid-state lasers, such as the fiber-guided TruDisk laser from TRUMPF with disk laser technology, or direct diode laser systems from IPG. EMAG is one of the pioneers in the use of solid-state lasers for the welding of powertrain components, and is convinced of its advantages. “The diode-pumped solid state lasers have an energy conversion efficiency of around 30%. So a 4 kW unit running at full speed uses only about 25 kW, including the cooling unit. That means a considerable cost saving for the customer, when you compare the operating costs of this system with those of traditional laser systems,” said Peter Loetzner, President & CEO of EMAG L.L.C. The use of solid-state lasers also permits welding without shielding gas, allowing further cost savings. Furthermore, solid-state lasers enable considerably faster welding for many applications. In terms of component quality, the heat input per unit length into the component is also reduced, which results in reduced welding distortion—removing the need for expensive reworking. It becomes clear why the ELC 160 HP can be called a “High Performance” welding machine. The entire design, including the process sequence, the technology used, and the compact, ergonomic structure of the ELC 160 HP is consistently aimed at performance and productivity. With the extremely short cycle times that can be achieved, EMAG is offering a highly attractive laser welding system for the manufacture of powertrain components, one that will no doubt prove very popular in the marketplace.