Why heavy machining becomes significantly easier with the new VMC turning/milling center from EMAG

The VMC 450-5 MT turning/milling center from EMAG ensures radically short, and unusually flexible, processes in heavy machining. How exactly does this all-purpose solution (perfect for a number of components) work?  And why can so many different industries benefit from it?

Flexibility and heavy machining—these two keywords are not usually associated with each other. After all, many particularly large components often run through a (too) complicated production process including various machining processes that take place in different machines. One consequence is that if another component needs to be machined, the operator must set up several machines again—which is not only time consuming, but can cause errors. With this background, the importance of process integration in machine manufacturing is generally increasing.Different turning, milling, grinding and gear cutting processes take place in one machining area. Theheavy machining specialists at EMAG have recently developed a highly flexible production solution for heavy machining—the vertical turning/milling center VMC 450-5 MT simplifies the entire process.

What is the impact of this approach in practice? 

When implemented, this technology opens up great opportunities, as this video shows.The complete main machining of a planetary carrier, including turning, drilling, milling and skiving, is now performed with only two VMC 450-5 MT machines from EMAG, plus a balancing machine—all three machines being integrated into an automation cell and connected by robots. So the component is now picked up no more than three times. That’s only half as many times as with traditional solutions for planetary carriers: The essential transmission component runs through no more than six different machines in heavy machining. This videoshows just how efficiently the linking with robots works (in this case VMC 450 MT units are used).

Higher Quality—Lower Energy Consumption

The benefits of this “leaning program” are obvious: component quality and process reliability increase; given perfectly coordinated machine operating cycles, downtimes are minimized and even energy consumption is low. Additionally, the operator no longer needs to set up six different machines when different versions of the part are lined up for production. The tool magazine with up to 80 slots plays a major role in this respect. It contains all the required tools or twin tools for various versions of a part. This is why the operator now only needs to replace the clamping jaws when re-tooling.

All-Purpose Solutionfor the Commercial Vehicle Industry, Aerospace Industry, etc.

The only remaining question is where can this machine can be implemented: For what type of components is it suitable? In this instance, the answer is very broad, because EMAG has a large standard modular system at its disposal and configures the machines individually. For example, various spindle versions, specific workpiece carriers or a tailstock are available. In conclusion, the machine was designed with the goal of enabling each user to perform complete machining including skiving or hobbing. The VMC 450-5 MT truly is an all-purpose solution.