Farmington Hills,  MI 
United States
  • Booth: 2025

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 and multi-functional production machines. The leader in 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 worldwide with their North American headquarters in Metro-Detroit.

 Press Releases

  • Westec 2017, Booth 2025: EMAG Presents World-Class Machining Quality with Modular Technology

    At Westec 2017, September 12-14 at the Los Angeles Convention Center, EMAG will feature manufacturing systems for precision metal components with the modular VL 2 vertical-pick up turning machine for the efficient machining of components up to 100 mm in diameter.

    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 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. 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 lightweighting automotive components. The latest addition to this diverse technology portfolio features 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 2025!

    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.

  • 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.

    VL machines are part of EMAG's modular standard series. As the term suggests, these machines are built on a common machine base but allow the use of an extremely wide range of technologies, similar to the modular platform systems seen in the automotive industry. There are now modular machines available for turning, gear hobbing, and chamfering processes; for grinding (chucked parts and shaft parts); for induction hardening; and also in special designs for laser welding or PECM technology. Essentially, they are available for virtually all the technologies offered by the EMAG Group.

    Automation Included

    The machine base of these modular machines is made out of MINERALIT® polymer concrete. This material has exceptional vibration damping properties, which is the basis for the machines' excellent process quality. The machine base supports a compound slide rest equipped with an X-axis and a Z-axis, which allows the working spindle to move. The working spindle is the heart of the pick-up automation system which is an essential part of every modular machine. It includes a parts storage unit in every machine, from which the pick-up spindle loads and unloads itself independently. This lowers non-productive time to an absolute minimum as there are only a few seconds between the machining processes. An optional measuring probe can be installed directly alongside the loading position, allowing time-optimized measuring of the parts. The designers have thought of everything to make these machines as efficient as possible.

    The VL Series—the Modern Approach to Turning

    The vertical pick-up turning centers of the VL series were developed particularly for the production of precise chucked parts. There are now five versions of the VL machine to cover the widest possible range of parts. The smallest machine is the VL 2, designed for chucked parts with a diameter of up to 100 mm. It is followed by the VL 4, VL 6, and VL 8 machines which allow for an increase of 100 mm in diameter with each model increase (see image). These additional models allow the VL series to cover workpieces up to 400 mm in diameter. Each VL machine is equipped with a tool turret with up to twelve (driven) tools for the machining of chucked parts. This turret is exceptionally dynamic; it’s very fast indexing cuts non-productive time to a minimum, which in turn reduces cycle times. The machines can also be equipped with a Y-axis in the turret for the machining of complex shapes. This greatly expands the number of possible applications of the machines. The fifth machine in the set is the VL 3 DUO with dual spindle.

    VL 3 DUO—Two Machining Areas Ensure Productivity

    The VL 3 DUO is the first dual-spindle machine in the VL series. Its parts capacity places it between the VL 2 and VL 4, allowing high-productivity manufacturing of chucked parts with a diameter of up to 150 mm. It's no coincidence that the majority of transmission gearwheels fall into this size category. Every aspect of the VL 3 DUO has been designed for high-volume production, which makes it the ideal solution for the machining of gear blanks that have to be churned out by the millions. The VL 3 DUO is pure performance. Including the parts storage unit, the VL 3 DUO has a footprint of no more than 13 square meters. That space houses the automation system, the parts storage unit, and two complete machining areas, each with its own working spindle and its own 12-station tool turret. This machine is ideal for production in two clamping operations – machining both sides of a workpiece in OP 10 and OP 20, respectively. Of course, the part needs to be flipped over between the two operations. With the TrackMotion automation system, EMAG has found an ingenious solution for this problem.

    TrackMotion—Modular Automation Solution for Modular Machines

    The TrackMotion automation system has been specially designed for modular machines and drastically simplifies the connecting of multiple machines. The example of the VL 3 DUO makes this very clear. The TrackMotion automation system is made up of two components: a track, which is a kind of rail routed behind the work area of the machines, and the TransLift, a gripper system that runs along on that rail. This NC gripper, which is programmed directly through the machine's control, provides the transportation of parts between the machines, as well as to and from the storage unit for raw and finished parts. The gripper has a Z-axis so it can also store the parts three-dimensionally, on top of each other, in stackers. This allows a huge number of parts to be stored in a very small space. The gripper also functions as a flip-over unit, turning the TrackMotion into a genuine all-purpose solution for the automation of modular machines.

    Modern Manufacturing with VL Machines

    EMAG's VL series of vertical pick-up turning centers offers a whole range of machines where everybody can find the perfect tool for their application. Whether as standalone machines, or linked with other modular machines, the VL series promises state-of-the-art production of chucked parts with top of the line quality, at rock-bottom unit cost.

  • In only a few other branches of industry are development pressures as enormous as in aircraft construction. One of the reasons is the fact that legislation is getting ever stricter about the CO2 emission of aircrafts at the same time as market expectations are of a rapidly accelerating growth in the sector. It is as a consequence of this development that aero engines are becoming a focal point. They need to show a reduction in fuel consumption, whilst – at the same time – having to guarantee greater propulsion values. It is obvious that such a development has a massive effect on the components used in the engines. They are made of extreme materials that have to with stand high stresses. The question is: how can one machine these materials with speed, precision and process integrity? The EMAG experts have a highly effective answer to this question: their ECM technology. Cutting processes often lose out in the decision making. The ECM machines from EMAG open up new opportunities in aero engine manufacturing.

    There is one important correlation to be found in the manufacture of aero engines: the higher the temperatures generated by the engine, the more efficient it is. The aircraft will consume less fuel over the same distance and increase its flying range. It is easy to imagine what this means for the materials used in the bowels of an aero engine. The higher temperatures irrevocably lead to the use of extremely hardwearing materials that perform better under stress.  But that is only “half of the truth” as, at the same time, many components are becoming more complex and still have to be machined at the highest precision. It is the only way to achieve the targets set over a decade ago by the aero engine sector, namely a 20% reduction in both CO2 emission and fuel consumption.

    An exceptional option for the aero engine manufacturing industry

    Of course, this is not an unfamiliar development, as the automotive sector provides another example. However, in aircraft manufacture it has more extreme consequences. And the industry has arrived at a crossroads. Experts estimate that over the next two decades air traffic will increase by 5 percent per annum. The prediction voiced by Airbus is that there will be a demand for 7,600 new engines every ten years. Although this offers great opportunities, it is certain that to conquer new markets the aero engine manufacturers will have to come up with constantly greater improvements. New aero engines are becoming top of the agenda.

    What are the manufacturing solutions that ensure the new high-performance engine components can be produced efficiently? ECM und PECM technology (Precise Electro Chemical Machining) from EMAG is an outstanding option, even though many developers and design engineers have not yet recognised the fact. This process comes into its own where complex components are to be produced in demanding materials, as it machines high-tensile alloys and similar materials with a minimum of tool wear. The surfaces are of outstanding quality – with no burrs and no changes in the microstructure of the material. In contrast, using cutting processes could lead to a number of problems. The temperatures generated by traditional machining methods often have a negative effect on the microstructure of the material. Tool life in the machining of high-tensile materials is short. And the high infeed rates required to make the machining process economically viable, make the machining of filigree geometries difficult. It should therefore not come as a surprise that the demand for ECM is increasing in aero engine manufacture. Since EMAG entered into this technology in 2009, a number of their machines have been delivered to the supply chain for aero engine manufacturers, where they are used to machine central components, such as blisks, disks and individual blades in nickel alloys at speed and with great precision.

    EMAG’s development of the process has been selective

    The electro-chemical process ensures a particularly soft removal of the material. The workpiece acts as positive anode and the tool as negative cathode. Between the two flows an electrolyte solution that dissolves metal ions on the workpiece. The contour of the cathode and the workpiece with their active, current-conducting sectors, are matched, to ensure that the material removal on the workpiece leads to the desired contour of the component. Contours, channels, grooves and cavities are generated without touching the component – and at the highest possible precision. And tool wear is minimal. With PECM, EMAG have developed the ECM technology further. The gap, through which the electrolyte solution flows, is particularly narrow; and the flow is optimised by a mechanical oscillation. This guarantees a particularly effective and precise removal of the material. The possibilities this technology opens up are best shown by the example of blisk productions.

    For the machining of turbine blade disks the specialists from EMAG have developed an ECM system equipped with 11 machining stations that carry out drilling, contouring, radius machining and polishing operations in one machine.  The high-tensile Inconel material is machined at a feedrate of 5 mm per minute, without burrs or negative thermal effects. The tolerances achieved are between 0.1 and 0.3 mm. The life expectancy of ECM tools is very high, making sure that the tooling costs in production are much lower than those using cutting tools for the process.

    Establishing feasibility in the laboratory

    The experts at EMAG ECM, with headquarters in Gaildorf, near Schwäbisch Hall, Germany, offer a complete and comprehensive service in this process. They see themselves as their customers’ partners in development. The centre of activities is an on-site laboratory, which offers the possibility to carry out feasibility studies and preliminary investigatioaHaHns on single- and multi-axes machines. In addition, the laboratory also offers comprehensive measuring systems (roughness, contour, coordinates).  

    The laboratory not only establishes the feasibility of a project, but also the cost-benefit ratio of the process with a view to the specific component and the material it is made of. This way, the customer will find out what component tolerances and cycle times he can expect to achieve.

    The general philosophy of the South German machine builder is another aspect of importance to aero engine manufacture. Right from the outset, the company relies on very close cooperation with its customers. The process is firmly implanted in the company’s strategy. This also means that, where required, customers receive in-depth training, to enable them to design and manufacture their own tools to suit their particular requirements.

    In cooperation with RWTH Aachen

    That the technological demands of the experts at EMAG ECM are far-reaching is shown by the fact that they work in close cooperation with the machine tool laboratory at the RWTH (Rhenish-Westfalian Technical College) Aachen. It is here that experimental analyses for the electro-chemical machining of materials establish the feasibility of the process and where improved cathode designs are simulated. The comprehensive objective is integrated optimisation. The process is constantly developed further with a view to the incorporation of new materials and changing component geometries.

    Large batch sizes, hardest possible materials, precision results without negative effect on the material, perfect surfaces – this is the background against which the outstanding market opportunities for the machine builder and their technology in aero engine manufacturing are generated. The company offers a modular machine concept that can be quickly tailored to suit individual component requirements. The customer also benefits from the generally high degree of EMAG expertise in the development and manufacture of machine tools. Pivotal innovations, such as Mineralit machine base, intelligent soft- and hardware interfaces and effective automation solutions are part of the company’s developments. It ensures that EMAG ECM can create tailor-made (P)ECM turnkey solutions. In fact, the machine builders at Gaildorf are convinced that their technology will prove indispensable for many future innovations in aero engine manufacturing. The clamour for the ECM process has begun.  

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