Efficient turning of hardened materials

These days,  cars are full of high-tech materials that ensure a long life for the individual components and make the car safe to drive. These materials are also less weighty, which reduces consumption levels. To ensure that they are machined in an economical way – using high-precision  processes – requires the right machinery and the correct process. When it comes to the machining of hardened surfaces, hard turning is a particularly efficient solution that  – compared to grinding–offers a radical reduction in both machining times and investment costs. With its VL 5 EMAG has a machine in its product range that is tailor-made for hard turning. Its design brings a number of advantages to the machine’s particular, highly demanding field of application.

The conditions faced by sub-suppliers and manufacturing companies alike have been the same for decades: optimal component  quality,  flexible  batch  sizes and  low  workpiece  costs. These are the kind of demands made by customers in all branches of industry and all fields of application.  However, it is particularly difficult to achieve in the machining of already hardened surfaces. Grinding, the method used most often for the purpose, is very time-consuming and known for its relatively  high  tooling  costs  and  energy consumption.  One  alternative  process that is being used more often, both in the small batch and the mass production of hardened workpieces, is hard turning. With good reason, as the process offers identical surface finishes and allows for the process chain to be shortened by a complete stage. Last, but by no means least, turning machines  are  noticeably  cheaper  than grinders and their energy consumption is lower. Unlike the grinding process, hard-turning can often be carried out dry  – a much more  environmentally  friendly method.

Design scores heavily in hard turning
In the VL 5 the turning experts from EMAG have created a tailor-made solution for the application of this innovative process.  Its design features make a particularly positive  impressionin handling the heavy stresses exerted on tools and machine during hard turning. For instance, its machine base is in Mineralit, a polymer concrete with a vibration resistance eight times that of cast iron. “A vibration resistant machine leads to an improved surface finish on all components it machines,  with tool life being much improved too”, says Peter Loetzner, CEO of  EMAG L.L.C. The vertical design is another feature that ensures an economical process,  with  the work spindle and the workpiece  located above the tool. This offers ideal chip flow  conditions,  with the material removed being taken out of the machine by a chip conveyor. All guideways  are  located  above  and  away from the machining are, keeping them safe from any possible ingress of chips or dirt. This increases the constantly maintained component  accuracy  and  reduces  the maintenance effort.

Another important quality feature of the vertical turning centres from EMAG is their integral automation. They all use a recirculating conveyor chain into which are inserted carrier prisms holding the raw-parts. The chain conveys the workpiecesdirectly  into  the  pick-up  station,  where they are picked up by the work spindle and then machined. Workpiece changeovers are very fast, as the distance travelled between loading and machining position is only 550mm. This leads to a massive shortening of the time span betweeNike Kyrie 5