38800 Grand River Ave
Farmington Hills,  MI  48335-1526

United States
  • Booth: 549

EMAG equipment covers the entire spectrum of machining processes in the metalworking industry, offering the latest technological advances in turning, drilling, milling, grinding, gear cutting, electro-chemical machining, laser welding, induction hardening and heat shrink assembly. Active in the automotive, aerospace, oil field, power generation and large equipment industries, EMAG is a trendsetter in the field of vertical turning and multi-functional, production machines, allowing the customer to process workpieces in a single set-up. The recent additions of gear generating lines of equipment through the acquisition of Koepfer and Samputensili expanded our capabilities even further and underscores our focus. 

EMAG Group Technologies :

  • Turning 
  • Milling 
  • Grinding
  • Gear Generating 
  • Hobbing 
  • Shaping
  • Shaving
  • Power Skiving
  • Laser Welding 
  • Electro-Chemical Machining 
  • Induction Hardening 
  • Induction Heating & Brazing
  • Heat Shrink Assembly 

The North American headquarters of the German based company is in Metro-Detroit and is an important partner the complete manufacturing line.

Staff from our sister company, eldec LLC, will also be available to discuss induction heating project as well as induction coil design.

Brands: Reinecker, Karstens, Kopp, Naxos-Union, Koepfer, Laser Tec, ECM, eldec, Richardon, Samputensili

 Press Releases

  • ECM as an alternative to metal cutting

    Electrochemical metal machining (ECM) is an established technique for burr removal. However, ECM can do much more. The EMAG ECM Company wants to use the process to replace conventional drilling, broaching and even milling. A number of advantages over machining speak in favor of this.

    "Structural change is in full swing and is also affecting the manufacturing industry," Franz Groß, Sales Manager at EMAG ECM in Heubach, is convinced. The advance of electromobility alone will reduce the total number of parts required in the long term. In addition, components would look different in the future. At the same time, the demands on materials, shape, complexity and precision are increasing. For example, more flow-optimized components are being developed based on examples from nature.

    One answer to these challenges is electrochemical metal machining (ECM). It can now supplement or even replace conventional machining in many areas - with advantages for quality and economy. According to Groß, "The wear on the tool is much lower than with machining production processes, but the workpiece itself is also protected, since it is not subjected to mechanical and thermal stresses."

    The tools are mostly made of the common stainless steels 1.4301 (X5CrNi18-10) or 1.4303 (X5CrNi18-10). On the one hand, they are particularly corrosion-resistant, but on the other hand, they can be machined well and do not need to be hardened. Depending on the material of the workpiece, surface finishes of up to Ra 0.5 micrometers and better are possible. This means that contours, ring channels, grooves or recesses can be produced with maximum precision without contact. "With a clever tool shape, hard-to-reach places can also be machined well and complicated shapes can even be realized inside the component," explains Groß.

    Electrolysis forms the basis

    ECM uses the physical-chemical process of electrolysis. Franz Groß explains how this works: "Tool and workpiece are in an electrolyte solution. A DC voltage with constant or pulsating current is applied to both. The tool forms the cathode and approaches a workpiece, the anode. A discharge occurs that dislodges material from the workpiece, which is carried away by the electrolyte solution." 

    Clean electrolyte flows in before each stroke. This is ensured by electrolyte management in a closed circuit. Powerful filters retrieve the removed material from the electrolyte, which is fed back into the process freshly cleaned. Groß: "Depending on the requirements, the electrolyte management forms an integral part in single-station machines or supplies several ECM modules as a separate component." Exchangeable cartridges, comb filter presses or microfiltration with backflushing are available for filtration. Automatic treatment keeps the pH in the neutral range. "The electrolyte should be changed once a year on average," the ECM expert recommends.

    A detailed explanation of the ECM process, including a video, can be found here: https://www.emag.com/technologies/ecm-electro-chemical-machining.html

    Material hardness does not matter

    Depending on the machining purpose, different processes can be distinguished: For deburring and rounding of intersections, the use of a stationary tool is suitable. With the moving cathode, the tool moves into the workpiece at a constant feed rate, comparable to drilling and broaching. Precise Electro-Chemical Metal Machining (PECM) is available for three-dimensional machining, in which the tool has a negative shape of the workpiece to be produced. "In the PECM process, an oscillating motion is superimposed on the feed and pulse electronics, which ensures more precise tolerances with a significantly smaller working gap," says Groß.

    Franz Groß adds, "Although the tool and workpiece never touch, we achieve feed rates of up to four millimeters per minute when broaching; for very filigree parts, it's still 0.2 millimeters." And this is practically independent of the material, "the only requirement is electrical conductivity." Unlike machining, the hardness of the material plays virtually no role in the process and process duration, he adds. "This also saves process steps because soft machining before hardening can be omitted."

    Machines for every need

    EMAG's CI and CS type machines are suitable for deburring and drilling. CI stands for Comfort Integrated and refers to machines with integrated electrolyte management. Groß says, "Two CI modules can also be combined to form the CI Duo, both of which then share the integrated electrolyte management system; this enables easy scalability of production capacities as well as entry into automation of the ECM process." CS refers to the standard variant, which is connected to a central electrolyte management system.

    Premium Integrated (PI) is a modular machine platform for the PECM process and replaces machining broaching and machining. It is based on the CI with the corresponding compact dimensions. "The entire machine technology with electrolyte management and electrical engineering is accommodated on a basic frame suitable for forklift trucks and requires only 5.5 square meters of floor space," explains Groß. 

    The modular workspace can accommodate two different modules: the PECM module with oscillator or the ECM lowering module. Both can be used for simultaneous machining of several identical workpieces. Here, too, there is a standard version (PS) for the use of several machines that share a central electrolyte management system.

    The machines are controlled by the widely used Siemens Simatik S7-1500 and Sinumerik 840D sl controllers with identical programming. Franz Groß: "For a new workpiece, all that needs to be done is to call up the appropriate stored type program and enter the relevant parameters."

    Infobox 1

    The advantages of the ECM process at a glance

    • Low tool wear (cathode), thus good prerequisites for series production
    • Surface quality down to Ra 0.05 micrometer
    • Precise machining
    • No thermal and mechanical influence on the components and thus no changes in material properties
    • Hardness, toughness and magnetic properties are not changed
    • Production of small and thin-walled contours
    • Very high repeat accuracy of surface structuring
    • Simple and highly efficient manufacturing process, no rework such as deburring or polishing necessary
    • Roughing / finishing / polishing in one operation
    • Machining of superalloys
    • Simultaneous machining of macro and micro structures

    Infobox 2

    About EMAG ECM

    EMAG ECM GmbH, based in Heubach, Germany, is a technology company for the electrochemical metalworking sector within the EMAG Group. One focus is deburring in the machining process. As it is often overlooked during planning, this can affect the economic efficiency of the overall system. EMAG closes this gap and thus offers the entire machining process, including deburring, from a single source.

    In addition, EMAG ECM has further developed the process in such a way that it can now be used instead of conventional machining drilling, broaching and machining. It offers solutions for the machining of extremely hard materials and the residue-free production of strategic components. ECM machines can be used, for example, to machine engine parts such as blisks much more productively than by machining. The range of products and services for electrochemical metalworking extends from consulting, development and prototype production to complete solutions.



    View of the CI machine from EMAG ECM: Users benefit from extremely compact technology with high-quality components and a favorable price/performance ratio.


    Many components in electric and hybrid motors, such as the rotor arm, also benefit from electrochemical metalworking. The process is faster, more reliable and more energy-efficient than many alternatives.


    A before-and-after comparison: The edge of the bore is absolutely burr-free after ECM machining (right).

    Franz Groß Sales Manager at EMAG ECM

    Contact Press & PR

    Markus Isgro
    EMAG GmbH & Co.KG
    Austraße 24
    D-73084 Salach

    Phone: +49(0)7162/17-4658
    Fax: +49(0)7162/17-199
    e-mail: misgro@EMAG.com


  • New Systems from EMAG

    The production of comprehensive manufacturing solutions from a single source is the main requirement for many mechanical engineering production planners. Typically, a general contractor would be responsible for the development of a complex line of interlinked machines with a variety of technologies. This provides the manufacturing company with two major benefits: the overall planning is easier (of the new factory) and a production partner that guarantees a perfectly designed, flexible, manufacturing solution, even for the most complex production situation. For years, the EMAG Group has been this partner, as it is one of the few machine builders that covers the entire process chain from soft to hard machining. Now, the experts are taking the next step with the creation of EMAG Systems and combining their project engineering expertise. The new company is the perfect partner for creating turnkey solutions and is responsible for the overall project – combining the experience and knowledge of the various EMAG branches when necessary. 


    For example, e-mobility: Here, the requirement for increased quantities is currently shifting the focus to the establishment of comprehensive production systems. Ultimately, this is the only way to be able to produce complex components such as rotor shafts or differentials in a process-consistent and cost-efficient manner. In the interlinked systems, for example, soft machining, hardening and hard machining take place in direct succession and numerous technologies from turning, drilling and milling to induction hardening and grinding are used. "When designing a complex system like this, there are naturally many questions during the planning phase ", explains Bernhard Böttigheimer, Managing Director of the new EMAG Systems. ” For example, users must understand the precise benefits and performance limits of the various tool processes, opportunities for the component assessed and a reliable process developed on this basis. To compile all this information, the user must have access to a large amount of internal technological expertise. At EMAG, we have been working toward this for years – we have a variety of core processes within the Group and are also developing in-house automation technology.”


    Combined System Expertise

    With all these tools at their disposal, EMAG has been enjoying growing success in the production of turnkey manufacturing solutions in recent years. The mechanical engineering company even underwent an audit by a major OEM, in which all processes and structures relating to the development of large production systems were successfully examined. The specialists regularly provide proof of their system expertise outside the automotive industry, as demonstrated by various solutions for oil production technology manufacturers. In the past, experts within the individual EMAG companies performed the corresponding project management. Why is EMAG Systems now taking on this task globally? "We are convinced that this business area is becoming increasingly important. The demand for complete production systems is growing because the range of products and parts is also increasing at many supplier companies and OEMs. This is putting more demand on production systems to be more flexible, and project engineering needs are being outsourced by many companies”, says Bernhard Böttigheimer.  – And for these customers, EMAG Systems provides a central point of contact with experience in comprehensive turnkey production. These specialists, based in Salach, Germany, will examine each inquiry in detail, and then determine which technologies are needed for the project. With this information they will form a project team, consisting of engineers from different EMAG companies – this team will work together to form a completely customized solution for the project. 


    Although EMAG Systems may be new, our team is not! We have a variety of experts from within the company, who have been responsible for similar projects for EMAG in the past. With this team, customers will benefit from the experience and in-depth knowledge of all the Group’s technologies. Within this new organization, the expertise of the employees will be combined, and the internal processes will be simplified. This allows those at EMAG Systems to focus on providing customers with a comprehensive process, while the individual EMAG companies focus on their specific technologies. 


    Initial Success Confirming the Path

    Overall, the EMAG Systems experts see their market opportunities as very positive. After all, in the automotive industry, for example, many supplier companies must position themselves much more broadly and establish independent production solutions for a larger number of different drive technologies - from the classic "combustion engine" and hybrid solutions to completely electric. "In this industry, the demand for our resource planning expertise is growing quickly” explains Bernhard Böttigheimer.  A second factor in the success of EMAG Systems is Industry 4.0. After all, Smart Factories that increase the productivity of a location, or improve process reliability are impossible without comprehensive, linked systems. This is where EMAG Systems and its project engineers play a critical role. A variety of current projects shows that this full scope approach is working in the market, especially in e-mobility. For example, EMAG is currently developing two production systems for machining a rotor shaft for European customers. "We are clearly on the right track", sums up Bernhard Böttigheimer. "With EMAG Systems, we intend to bring our long-standing project engineering expertise to the market in a selective manner, while continuing to grow over the next few years and at the same time pressing ahead with the technological development of production systems. We are in an ideal position for this."  


    Contact for press and publications

    Markus Isgro

    EMAG GmbH & Co.KG

    Austr. 24

    D-73084 Salach, Germany

    Phone: +49(0)7162/17-4658

    Fax: +49(0)7162/17-199

    E-mail: misgro@emag.com


  • eldec has solutions

    Shrink fitting using induction heat simplifies assembling and disassembling metal parts. The process is quick, and the joints are neat and precise. Gentle, non-contact heat expands the outer mating part evenly without negatively affecting the microstructure, while the inner part is inserted at ambient temperature.  As the outer component cools it creates a firm bond. A thermoelectric device on the generator measures the temperature and creates a setpoint level of heat that cannot be exceeded, which protects the parts from overheating in some areas and not heating enough in other spots.  A similar process can be used to remove a mated component for repair or replacement.

    At eldec our technicians will review your parts, select an appropriate induction power supply and design custom inductors specifically for your components, ensuring top rate efficiency and quality joints. They can also help setup the perfect recipe of generator settings – setpoint temperature, length of time, energy level and magnetic frequency – to fit your production situation.

    Induction Shrink Fitting Systems and Processes

    eldec manufactures two lines of robust, medium frequency induction generators that are appropriate for shrink fitting and de-coupling component parts, the ECO LINE and the CUSTOM Line. These two lines of power supplies are often used in manufacturing operations for automotive, aerospace, oil/gas production and distribution, power generation, medical device industries and more.  Additionally, our experience with custom manufacturing induction heating coils as well as processes used in a variety of industries make us a valued supplier of induction shrink fitting systems.  Don’t take our word for it. Visit our website and see how Elektror airsystems, a manufacturer of industrial fans, updated their aging induction system with a safer, more efficient one from eldec. In this video they explain how the new eldec induction system improved their ability to connect a stator housing with a motor winding.

    Common Applications

    Induction can uniformly and gently heat the outer portion of a motor housing or the ID of a bore without overheating or damaging any one area, making shrink-fit connections fast and simple to assemble and disassemble. This non-contact process is precisely controlled and traceable, and can be adapted for:

    • Joining electric motor housings
    • Joining motor shafts and rotors
    • Replacing or aiding in press fit processes
    • Gear insertion
    • Helping to maintain concentricity of components being assembled
    • Other interference fit assembly applications

    Learn more at www.inductionheatingexperts.com and see us in booth 549.

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