EMAG has developed a compact manufacturing solution based on its VL8 vertical turning lathes that expedites the machining of large brake drums for a leading manufacturer in the commercial vehicle segment.

The vertical structure of EMAG pick-up machines is among the factors that helped to compress the entire machining process into just three operations. EMAG provides all components of the solution, including the machines, robotic handling, peripherals, clamping devices and tools. The customer therefore receives a co-ordinated system, designed for maximum productivity. EMAG also takes care of service and maintenance.

In terms of the process, raw parts arrive on pallets, from where the robotic rail automation system takes over all component handling tasks. In Op 10, which takes place on two machines due to the cycle time, all turning work on the first side of the brake drum is performed, both inside and outside. The part is turned over between Op 10 and Op 20, allowing the bolt ring on the brake drum to be machined, including drilling the holes for the bolts. This is possible via a turret on which driven tools can be used. Op 30 follows with the final balancing work, which is also performed on a system developed by EMAG.

The flexible system is capable of adding another station, such as a measuring station, before the finished part is stacked on its pallet. Also, the VL8 machines from EMAG can be optionally equipped with measuring probes that can carry out pre- and post-process measurements.
EMAG’s VL8 offers a chuck diameter of 500 mm, while the pick-up spindle picks up workpieces with diameters as large as 400 mm.

For further information
www.emag.com

To upgrade its plant and instigate 24-hour production later this year, High Wycombe-based subcontract machining firm EV Engineering has bought four Japanese-built Okuma turn-mill centres from sole UK agent NCMT. Founded in 2001 by David White, the subcontractor specialises in producing complex prismatic components in exotic materials for the oil, gas and energy sector, which accounts for around three-quarters of the firm’s turnover.

It was at EMO 2005 – where Okuma launched its first Multus turn-mill machine with a B-axis spindle – that EV Engineering became interested in the Okuma range of machinery. The five-axis Multus features collision avoidance in real-time, both in-cycle and in-manual mode, preventing collisions and minimising unscheduled downtime. It was the latest version of this Multus machine, with a sub-spindle and steady rest, which arrived on the shop floor in 2018.

“It’s an extremely rigid, slant-bed lathe on which we carry out a lot of machining, including deep-hole drilling in titanium and Inconel,” says White. “We don’t consider it feasible to leave it producing high-value parts unattended, so we don’t intend to add automation on this machine. The same currently goes for the Okuma Genos L3000 that we bought the same year, as it’s a two-axis lathe with live tooling dedicated to producing smaller parts in lower volumes.”

He adds: “It is our intention, however, to retrofit a robot to the Multus U3000-2SW multi-tasking B-axis lathe with automatic tool changer, lower turret and sub-spindle that we installed in December 2019, to give us the benefit of lights-out running.”

An Okuma Space Turn LB3000-MY lathe with live Y-axis turret is currently on order and will be fitted with a Belgian-manufactured RoboJob Turn-Assist.

For further information
www.ncmt.co.uk

Global sales of e-bikes are set to reach about 40 million units by 2023, and Tornos Swiss-type sliding headstock lathes, services and software are already helping e-bike component suppliers keep pace with that growing demand.

Today, there are 200 million e-bikes registered in China, according to the country’s Ministry of Industry and Information Technology, with 30 million more e-bikes being added each year.

Moreover, china has more than 700 e-bike manufacturers, accounting for 80% of global turnover.
One of the market’s most popular e-bike drive units relies on a crankshaft featuring a splined chromium steel (16MnCrS5) axle, and these parts are commonly machined on Tornos EvoDeco machines.
Available in four diameter ranges (10, 16, 20 and 32 mm), the EvoDeco series offers high levels of flexibility. Tornos says that no other machine can engage as many tools at the same time. The machines are equipped with the latest-generation technology and boast a powered spindle with asynchronous motor. Users profit from acceleration rates and stopping times that are four times faster than alternate machines on the market, reports Tornos.

As electrification drives innovation in mobility, the EvoDeco helps manufacturers keep pace with the evolving e-mobility landscape. For example, EvoDeco models feature four completely independent tool systems, 10 linear axes and two C axes, while continuous thermo-stabilisation ensures precision. Accessibility and simple programming are further hallmarks of the EvoDeco range.

Thanks to its experience in sectors such as electronics and automotive, Tornos says it has the know-how and solutions to produce the connectors needed for e-bike batteries, sensors and displays, as well as connectors for e-bike charging stations.

For further information
www.tornos.com

The cost-effective Vulcan series of machines from the Engineering Technology Group (ETG) now includes the new TC250 turning centre, one of the most compact models in the range.

Available in four variants, the TC250 base model is the entry-level cost-efficient option with a single spindle and turret. This machine has a maximum turning diameter of 316 mm, a swing-over-bed of 600 mm and a working length of 435 mm. Working within this area is a spindle with a speed range from 25 to 3500 rpm and a bore of 77 mm diameter.

TC250 models feature a 45° slant-bed construction to ensure maximum stability, while ensuring the effective removal of swarf from the work area.

Adding to the TC250 base variant is the TC250M for manufacturers seeking a reduction in secondary operations through the application of live tooling stations on the turret. The TC250M utilises a servo turret to instigate live tooling with speeds from 25 to 4000 rpm.

Complementing the TC250 and TC250M is the TC250L – a long-bed version that extends Z-axis travel from the standard 490 mm, to 1340 mm. A TC250ML model incorporates both live tooling and an extended bed.

All four machines in the TC250 series are equipped with direct-drive servo motors for smooth and rapid traverse movements of 30 m/min in the X and Z axes, with a cutting feed rate from 0.001 to 500 mm/rev. The standard offering from ETG includes a 3-bar coolant pump, 190-litre capacity coolant tank, programmable tailstock, eight-position hydraulic tooling turret, three-colour beacon light, toolkit, work light, heat exchanger for electrical cabinet, chip conveyor, automatic lubrication system, automatic tool probing and automatic part catcher.

For further information
www.engtechgroup.com

Since 2015 KAMPF Schneid- und Wickeltechnik GmbH & Co KG has been rapidly accelerating its integral digitisation. While the company initially focused its efforts in this direction on products and services, it is now equipping its production plants for the era of Industry 4.0 through its close innovation partnership with DMG Mori.

The KAMPF production site in Dohr clearly demonstrates the status of the digital innovation process. Here, DMG Mori ‘Planning Solutions’ has been in use for several months. “This has made us more efficient and flexible and, with a 30% reduction in throughput times, we can respond faster,” says Dr Stephan Witt, head of engineering & material management.

KAMPF has now initiated entry into its next evolutionary stage of digitisation with the installation of a CTV 250 vertical turning centre from DMG Mori.

“The result is greater integration and interaction between the office and shop floor, or rather between planning, machine tools and our employees,” explains Marc Jobelius, plant manager.

Thanks to the ‘Job Import’ function, the operator can import job orders directly from ‘Production Planning’ into the CELOS system and start processing immediately. Also, PDA information can now feed directly from the CELOS application connector.

In another joint KAMPF/DMG Mori pilot project, ‘real’ data from the shop floor is now being recorded in ‘Production Feedback’ and written into a central database via an integration layer. This will ultimately result in an extensive data pool from which realistic projected figures for previously unknown work steps will be calculated using algorithmic pattern-matching before transfer to new planning processes.

For further information
www.dmgmori.com