EMAG LLC  

38800 Grand River Ave
Farmington Hills,  MI  48335-1526

United States
248-477-7440
  • Booth: 1045

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, skiving and laser welding. 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 German based company is an important partner in the realization of complete manufacturing lines world-wide with their US representation located in Metro-Detroit. For more information visit www.emag.com


 Press Releases

  • (Jan 10, 2019)

    EASTEC 2019, Booth 1045: EMAG Presents World-Class Manufacturing Systems for Precision Metal Components

    EMAG, a leading supplier of manufacturing systems for precision metal components, announces its participation in EASTEC, the leading Northeast manufacturing trade show. This three-day event will be held May 14 - 16, 2019 at the Eastern States Expositon in West Springfield, MA. EMAG USA will feature manufacturing systems for precision metal components with a special focus on the creation of components in the aerospace and automotive industries.

    About EMAG:

    The EMAG Group covers the entire spectrum of machining processes in the metalworking industry. Whether chucked components or shafts, the companies under the EMAG umbrella offer the latest technological advances in order to optimize a manufacturing solution that satisfies 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 be an important partner in the realization of manufacturing solutions for the production of transmission, engine and chassis workpieces, as well as for the 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
    • Skiving

    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.

  • When EMAG launched the new TrackMotion automation system in 2015, it quickly became apparent that it not only focused on transporting parts, but on the perfect combination of machine tool, raw parts storage facility and a standard automation solution to create a highly efficient production line.

    The consistent adjustment of the automation to the modular machines from its internal production makes it possible to create manufacturing systems using a modular kit.

    So it will come as no surprise that EMAG is now unveiling another world first, a direct development of the modular machines in combination with the TrackMotion automation system the VL 3 DUO.

    When you first see the machine, you’ll immediately notice how compact it is. “We need just 13 m² (140 sq ft) to install the complete VL 3 DUO,” explains Peter Loetzner, CEO at EMAG L.L.C. “For a twin-spindle vertical pick-up turning machine, that is a fantastic size. Even if the machine is combined with a raw parts storage facility and the TrackMotion automation system, the dimensions for a complete manufacturing system for chucked parts up to 150 mm (2 in.)  is almost laughably small. That makes the VL 3 DUO one of the most compact and efficient systems available from EMAG,” says Peter Loetzner, glowing with pride.

    Gearbox Parts at a Glance

    With its parts ranging up to 150 mm (2 in.) in diameter, the VL 3 DUO is ideal for the manufacturing of gearbox components, for example, machining blanks for gear wheel production. “Gearbox components such as gear wheels must be manufactured in very large quantities. The standard production process is always the same: in OP 10 and OP 20, both sides of the gear wheel blank are machined by a turning process and the surfaces are prepared; the gear cutting process follows in OP 30 and deburring takes place in OP 40,” explains Peter. “The VL 3 DUO is, of course, primarily focused on the first process in this machining chain, in other words OP 10 and OP 20, which can be implemented perfectly with our system.” What the Product Manager is saying becomes apparent when we look at the VL 3 DUO in detail.

    TrackMotion Modern Part Management in the Manufacturing Process

    The VL 3 DUO can be fitted with EMAG’s TrackMotion automation system as an option. The automation system consists of three central parts, the track (i.e. the rails) on which the TransLift NC gripper runs and the raw parts storage facility. The entire system is very compact and runs directly behind the machining areas of the VL 3 DUO. The TrackMotion always focuses on the individual component. Each transport process only moves a single component which allows for significant benefits for component management. The increased mobility of the TransLift, including the Z-axis, means that stackable pallets can be used on the raw parts storage facility, making it possible for the raw and finished parts to be stacked with minimal space requirements. In addition, the TransLift is also used as a changer between the two machining operations. This means that the TrackMotion automation system provides everything required for compact manufacturing on the VL 3 DUO: an extensive parts storage area that accommodates up to 400 parts and a fast, flexible parts transport system between the various manufacturing stations.

    Modular Machine with Two Machining Areas

    Like every modular machine, the VL 3 DUO has its own parts buffer and a pick-up spindle in each machining area. The TrackMotion automation system loads the individual part pallets on the parts buffer as they shuttle between the loading position near the machining area and the rear section of the machine. From there, the working spindle takes the raw part, transports it into the relevant machining area and places the part back onto the appropriate pallet after it has been machined. Immediately next to it, the subsequent part is waiting to be picked up by the spindle, so that only a few seconds pass until the next part is being machined.

    The machining areas are arranged in a mirror constellation and each has its own working spindle which, with a rating of up to 18.1 kW and torque of up to 142 Nm, has plenty of power for high speed, precision machining.

    In addition, each machining area has a tool turret with twelve tool positions which can be fitted with turning tools or driven tools. “The turrets can also be fitted with an additional Y-axis to extend the range of uses of the machine even further,” explains Peter.

    Ideal Supplement to the Modular Series

    The VL 3 DUO adds a highly productive, compact manufacturing system for large-scale production to EMAG’s modular machine family.

    “Its real strength can be seen when it is connected to other machines in the modular machine family,” continues Peter. “Let’s look at the example of gear wheel production mentioned above. If we supplement the VL 3 DUO with the VL 4 H, the modular gear hobbing machine from EMAG, and a VLC 100 CC or VLC 100 RC, the vertical chamfering and deburring machines, we create a manufacturing system for gear wheels which is completely linked using the TrackMotion automation system, with a very small footprint. The whole thing is made possible by the standard structure of the modular machines, the integrated automation system and the fact that the transfer height between the machines is always identical – it’s simply brilliant! In other words, almost as simple as using building blocks,” says Peter Loetzner in conclusion
  • ECM technology from EMAG –

    a close to indispensable part of any innovation in aero engine manufacturing

    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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