Closely interlocked and splined

MAG has built itself a reputation as a specialist for cold rolling of splines in power trains. The tried-and tested Ex-Cell-O technology can now be found in modern, energy efficient and hydraulic-free high performance cold rolling machines of the XK series. The machine tool manufacturer has now grouped the company's cold rolling specialists together in the new Business Unit Cold Rolling Technology.

Jürgen Schmid, Head of the Business Unit Cold Rolling Technology at MAG IAS in Eislingen shared why the company is pooling its know-how concerning its cold rolling technology in a dedicated business unit, which includes design and manufacture of the XK series.

Mr Schmid, why did you combine the cold rolling specialists into one business unit?

Schmid: Cold Rolling technology has a fairly long tradition at MAG and has its roots with Ex-Cell-O. We have many years of experience in this interlocking technique. Sales, Development, Design, Manufacturing and Service for the XK series were previously spread over several MAG sites. So that we could give customers even better advice and develop solutions for their specific gearing tasks together more effectively, we decided to pool this know-how in a topperforming team for Cold Rolling Technology in Eislingen.

Where do you see the main benefit for customers?

Schmid: All the staff in the new business unit focus entirely on the core business cold rolling technology. Thanks to the lean organisation structure, there will be less frictional loss and we will be able to carry out research and development more effectively due to the improved proximity. The customers also benefit from this directly of course: they only have one point of contact for all their questions regarding cold rolling of toothwork – and this can be on any matter including maintenance and service as these areas are also integrated in the new business unit for our XK cold rolling machines.

And where do you see your main business in the future?

Schmid: In cold rolling of all the possible profile types and gear toothwork of course, whether for power trains, armature shafts, drive shafts or axle shafts and kingpins. And here we are not just concerned with the power train area but also cover subcontractors in all industries– splines, screw threads, grooves, knurls and evolvent-shaped profiles are required in many industry sectors after all. I also see a considerable need in the service area: rebuilds, retrofits and retoolings are increasingly being requested by customers and we are happy to meet this challenge.

As part of the company's technology-related restructuring, MAG has combined all cold rolling technology departments at its Eislingen site. All staff involved in cold rolling are now grouped together in one dedicated business unit. Sales, development, design and manufacturing of gearing technology are now grouped more closely together and can more easily discuss matters and come to an agreement. "It is well-known that lean structures with short decision-making paths lead to quicker decisions and solutions and it is not only our customers that profit from this," says the Head of the new business unit, Jürgen Schmid, explaining the decisive advantage.

As part of the company's technology-related restructuring, MAG has combined all cold rolling technology departments at its Eislingen site. All staff involved in cold rolling are now grouped together in one dedicated business unit. Sales, development, design and manufacturing of gearing technology are now grouped more closely together and can more easily discuss matters and come to an agreement. "It is well-known that lean structures with short decision-making paths lead to quicker decisions and solutions and it is not only our customers that profit from this," says the Head of the new business unit, Jürgen Schmid, explaining the decisive advantage.

MAG's cold rolling machines (series XK 2, 6, 8 and 12) cover a broad range of applications. As regards toothwork, diameters of up to 120mm and module 3 are possible. In addition to highly complex rolling tools, the new business unit will also manufacture prototypes or small batches for customers. Rolf Ziller, Head of Development & Sales Cold Rolling Technology adds: "We provide our customers with a complete solution. To achieve this, we utilise our core competence in metal forming and our manufacturing is carried out with adapted machine and tool concepts specifically designed for the purpose. The customer environment with the necessary automation technology is also taken into account of course. We will be developing the service side in this compact unit with a distinct focus on technology to ensure we meet our customers' needs even more precisely."

The XK cold rolling machines of series XK 6 and XK 8 are energy efficient thanks to their electro-mechanical axle drive and can be used for largescale production of splines on drive components. The XK 12 rounds off the top end of the product range and is especially for longer and more solid shafts up to 5,000 mm in length. The demands of the Asian market are efficiently met by the parallel manufacture and supply of series XK 2 and XK 6 in MAG's plant Changchun. "The XK 6 in particular is a very robust machine with simplified tool settings for a broad range of applications," emphasises Jürgen Schmid. "Here, we are particularly targeting the manufacturers in the Asian sub-contractor market who massproduce drive shafts both flexibly and cost-efficiently."

But new machines and rolling tools are not the only focus of MAG's cold rolling team - the customer base for rebuilds, retrofits and retoolings of older Ex-Cell-O machines is also experiencing rapid growth. "We have already overhauled a large number of old machines and lines or carried out a complete retrofit," says Rafael Schweda, Team Leader Cold Rolling Machines / Overhauling / Retrofits & Service. This is why the service experts for the XK series will also be integrated into the new business unit.