The trend towards miniaturization of components
and the simultaneously growing demands for greater precision is unmistakable.
For these applications, EMAG has developed the modular VG 110. The trend towards miniaturization of components
and the simultaneously growing demands for greater precision is unmistakable.
For these applications, EMAG has developed the modular VG 110.
The VG series is for high-speed machining of small and very small workpieces of 2mm to 60mm in diameter.
The VG 110 is a production grinder for the machining of large batches of small and very small high-precision workpieces that use the following technologies:
internal cylindrical grinding
external cylindrical grinding
out-of-round grinding
the combination process of hard turning plus grinding.
"The VG 110 provides the user with a choice to either grind the 'traditional' way or profit from the advantages offered by the combination of turning plus grinding on one machine. Where the process specification permits, sections of the workpiece are soft or hard finish-turned and only finish-ground - in the same setup (and most frequently after having first been pre-turned) - as tolerances demand. This not only improves component quality but also reduces cycle times. It also limits the wear and tear of grinding wheels and, consequently, the number of dressing cycles required. This makes the VG series an attractive proposition for the manufacturing of many small, very precise components," said an EMAG spokesperson. These components include:
cup valve pistons and valve bodies for modern fuel injection systems
rollers and sleeves for monoblock injection pumps and nozzles
cam rings for fuel injection and power steering pumps, parts for air conditioners in passenger cars, for radial piston pumps and motors
internal and external polygons on tool shanks or drive shafts
cylinder liners
pinions.
"The high-grade Mineralit polymer granite machine
base offers maximum thermal stability and has an exceptional damping effect. X-
and Z-axis are separate, to ensure that the highest machining quality is
maintained on small workpieces. The vertical Z-axis is equipped with a linear
drive. This allows the grinding spindle(s) to carry out short, rapid oscillating
strokes. The X-axis determines machining accuracy and, as a vertical axis, is
completely removed from the machining area. The high-resolution measuring system
is only 100mm away from the machining process. Depending on the application,
this allows for tolerances of 0.5 - 1 µm to be held. The work spindle is a
frequency-controlled AC motor spindle. Low mass and a high torque rate create
particularly outstanding dynamics," said the spokesperson.
"Short travels, high speeds, a high degree of rigidity and an integrated cooling system (for spindle motor, grinding spindles, linear drives and electrical cabinet) help achieve short idle times, high output rates and excellent precision. To compensate for the deflection of the grinding arbor, the tooling system can be equipped with a swiveling E-axis.
"The modular machine concept allows for the tooling equipment to be adapted to suit individual machining requirements. The following machine variants are available:
one or two internal grinding spindles for cylindrical or out-of-round grinding
one internal or one external grinding spindle and a turning tool
"The VG 110 offers all cutting-edge grinding technologies including:
grinding tools: ceramic or electroplated CBN grinding wheels
sensory analysis modules: adaptive grinding, touch-recognition, touch-dressing
dressing technology: dressing spindle for the use of diamond dressing rolls.
"The control system used is a SINUMERIK 840D. Programming and operation of the machine are made easy by the operator-friendly EMAG software.
"To achieve short cycle times, it is more important than ever to keep loading times short also. Loading small workpieces through the work spindle results in very short loading times of around 1.5 seconds. Workpieces that cannot be loaded through the spindle are taken into the machining area by a shuttle in inserted into the workholding unit by a lift-up loader. Workpiece handling times depend on the workholding unit and can be as low as four seconds," the spokesperson said.
"The VG 110 fulfills all the demands made on a modern production grinder such as:
high output rates
exceptional machining quality
short cycle times
low component manufacturing costs
the application of cutting-edge grinding technology.
"The VG can be used as a stand-alone, but can also be integrated into a fully automatic production line as a self-sufficient link that accommodates turning as well as internal, external and face grinding operations.
Highly flexible in its application, of extremely rigid construction, offering short strokes, high rapid traverse speeds and featuring an integrated cooling system and workpiece loading through the spindle, the machine stands for high output rates, highest precision and the lowest idle times imaginable. And the footprint (5.3 m2) is extraordinarily small too," said the spokesperson.
For more information contact:
Gary Hulihan
EMAG L.L.C.
38800 Grand River Avenue
Farmington Hills, MI 48335
248-477-7440
Fax: 248-477-7784
E-mail: ghulihan@emag.com