Electric cars still account for a relatively small proportion of total car sales, and a trend toward rapid growth for electric car production is still a long way off. But there are exceptions, as demonstrated using EMAG Scherer’s technology at a supplier in Central America. A total of 12 CNC vertical turning centres of type VDZ 520 XL ensure that up to 3000 stator housings, used solely in electric car motors, are machined every day.

Eight processes take place on the stator housing in only 240 seconds of chip-to-chip time. Ultimately it is possible to produce about 320 components per machine and day, although the customer ordered six machines to produce higher quantities. In the meantime, 12 machines are in use, which shows this solution is meeting expectations in every respect.

The finished component has a wall thickness of just 4 mm, with tolerances of only 0.016 to 0.25 mm and very precise roundness. At the same time, there are many bore holes and grooves, and the geometry is not rotationally symmetric.

Using the VDZ 520 XL, eight cutting processes take place in succession on the injection-cast blank – from the highly precise roughing and finishing of internal surfaces, external connecting surfaces and sintered bushes, to the milling of grooves and the drilling or milling of various cross and oblong holes.

The customised clamping solution from SAV has a special role, aligning and centring the sensitive component with high precision. Furthermore, the entire design of the machine is advantageous. Its vertical machining configuration ensures optimal chip flow despite the closed stator housing, while its synchronous drive technology with 64.4 kW power and 1110 Nm nominal torque ensures reliable, quick processes.

For further information
www.emag.com

Hardinge has introduced its newly upgraded Hardinge Talent 42/51 multi-tasking CNC lathe, which the company now manufactures in the USA. Designed to work with a number of different types of work-holding systems, the new Talent 42/51 provides machine shops with a highly versatile turning centre complete with new Fanuc 0i-F Plus control.

“We’ve been a proud partner of American manufacturing since the 1890s and are excited to have our Talent series lathes produced under the same roof as our Super-Precision turning centres at Hardinge’s Elmira, NY location,” says Jeremy Michael, the company’s director of turning and milling. “It is through domestic production that Hardinge can provide the quality, flexibility and responsiveness required by our customers to help them succeed in today’s competitive manufacturing world.”

The new Talent machine offers a combination of features for accuracy, flexibility and durability in a compact design. Notably, the novel collet-ready main and sub-spindle concept will increase part accuracy and improve surface finish, says the company.

Other key features of the upgraded model include machining specifications up to 12 axes, six spindle axes and two paths. Users can perform four-axis simultaneous or 3+2 axis machining. Multiple configurations are available, including live tooling, Y axis and sub-spindle variants.

With the FANUC 0i-F Plus CNC system, users can take advantage of conversational programming via Manual Guide i, as well as improved processing power with 400-block look-ahead capability and enhanced safety thanks to FANUC’s Dual Check safety function.

The upgraded Hardinge Talent 42/51 made its debut appearance at the recent PMTS exhibition in Cleveland, Ohio.

For further information www.hardinge.com

A CNC turning centre provides potential users with multiple choices to configure a machine to their precise needs. Launched by DMG Mori at the EMO Milano exhibition in October, the NZ platform is available as a DUE, TRE or QUATTRO model, having two, three or four turrets respectively. Each also has an 80 mm Y axis and the possibility of having a -10 to +100° B axis. The built-in 16 kW/12,000 rpm/24 Nm motor has either 12 live stations for VDI 30 tools or 16 stations for VDI 25 tools.

DMG Mori’s new machine is available in two bed sizes, a short version for workpieces up to 740 mm long and a larger version for workpieces to a maximum length of 1290 mm. A magazine for feeding bar stock up to 65 mm diameter is available, with the potential for the chucking of billets up to 120 mm diameter. Even with a 4 m bar feed, only 17.8 sq m of shop floor space is required.

Suitable for use on the long-bed lathe, but also possible on the short-bed version, an optional, double-sided, twin spindle can be mounted in the Z axis between the 5000 rpm (optionally 7000 rpm) main and counter spindles. Able to accept up to 65 mm diameter workpieces, it effectively divides the machine into two twin-spindle work areas and may be used for turning at up to 4000 rpm. When machining longer workpieces, it functions as a hydraulic steady rest or a Swiss-type unit with a 5000 rpm rotating guide bush.

A symmetrical, thermally stable bed ensures stability and precision during machining. Other merits of the machine include ergonomic accessibility to the working area and efficient chip evacuation.

For further information
www.dmgmori.com

Building on the strengths of previous generations of Miyano fixed-head turn-mill centres, the BNA-42SY is Citizen Machinery’s latest addition to the range. The CNC lathe is the first BNA model to have a 12-station turret giving ±35 mm of Y-axis movement, all tool positions now being live, and a new design that lends itself to easy automation.

Compared with current BNA models, machining efficiency has been upgraded by more powerful spindle motors, which are rated at 7.5/5.5 kW (15min/cont) for the 6000 rpm main spindle and 5.5/3.7 kW for the 5000 rpm sub-spindle. Acceleration and deceleration are quicker on both spindles, improving productivity further by minimising idle times.

The machine’s rigid bed, the weight of which is now 1823 kg, brings thermal control advantages and more capacity to house a larger coolant tank. Notably, the base casting has been prepared with space at the right-hand side for robotic load/unload equipment. If a user intends to take advantage of automation, the machine is available with a swarf conveyor that exits to the rear as an option. Users may deploy the automation solely for unloading components that have been turn-milled from bar stock up to 42 mm diameter, either directly from a spindle or via a parts catcher and conveyor. Alternatively, or in addition, it may load and unload billets or near net shape workpieces like castings or forgings up to 135 mm in diameter.

Mounting points have been included to provide an option to add an overhead gantry if only chucking is to be carried out, in which case a raw material stocker can be positioned to the left of the machine in place of the bar magazine.

For further information
www.citizenmachinery.co.uk

Japanese machine tool manufacturer Okuma has incorporated a robotic arm inside its CNC turning centres for the automated production of shaft- and chuck-type components. The sole UK and Ireland agent for Okuma is NCMT.

One of the first Okuma lathes to benefit from an internal ‘Armroid’ (Arm Robot Intelligent Design) workpiece load/unload system is the LB 3000 EX II, one of which is available for demonstration in NCMT’s Coventry showroom.

Three different end-of-arm effectors are available for performing different tasks. One is for blasting air or coolant within the cutting zone. This effector can be programmed to follow the cutting tool for breaking up stringy swarf or to clean down the whole working area, greatly improving chip management.

A roller end effector provides support under a shaft component during cutting to minimise chatter.

In combination with a workpiece stacker, the third end effector is a two-finger gripper for automatically holding shaft-type workpieces around their circumference for loading and unloading, with total weight capacity being 5 kg. All three end effectors are stored within the machine for automatic exchange by the robot.

It is possible to integrate a longer, more powerful Armroid into a second Okuma turning centre, a Multus B250II multi-tasking lathe. The robot arm handles workpieces up to 10 kg and possesses a fourth type of end effector with a three-jaw gripper for holding billets around their end faces.

Armroid systems are suitable for high mix, small batch work. The extended periods of unattended running release the operator to carry out duties in other parts of the factory. However, the cells are not for the lights-out production of large quantities of the same part due to the limited number of workpieces that the stocker can accommodate.

For further information
www.ncmt.co.uk