• January 19, 2021
  • Register
  • Sign in
    • Forgot Password ?
    OR
    • Sign in
  • FAQ
  • Contact
  • About us
www.cnctimes.com logo
  • Editorials
    • NEWS
    • CASE STUDIES
    • INTERVIEWS
    • SUCCESS STORY
    • PRODUCT SHOWCASE
    • TECHNICAL ARTICLES
    • BLOGS
    • VIDEOS
    • NEWSLETTERS
  • Forum
  • EVENTS
  • INVENTORY
    • INVENTORY LISTINGS
    • AUCTION LISTINGS
    • WANTED LISTINGS
  • BUSINESS LEADS
    • BUYERS
    • MANUFACTURERS
    • DEALERS
  • SHOWROOM
  • JOBS
  • Register
  • Sign in
  • Contact
  • Advertise
  • Feedback

Information

Please login to give the feedback.

Information

Please login to give the feedback.

  1. Home
  2. News
  3. VL 1 TWIN from EMAG: Drastically Lower Unit Cost for Bevel Gears

VL 1 TWIN from EMAG: Drastically Lower Unit Cost for Bevel Gears

23 June, 2020
  • Tweet
  • share via email
Your comment has been posted.
We have sent you a verification email. To verify, just follow the link in the message.
Some technical error. Please try again.

Bevel gears found in passenger vehicles are mass-produced. Supply companies produce these gears, essential for differentials, by the million—and it’s no wonder, since there are four of these in every differential. The number of all-wheel-drive vehicles, which include two differentials each, is continuing to rise leading to an increase in bevel gear output volume, and bringing more attention to the production process for this part. Supply companies are searching for new mechanical engineering solutions that guarantee considerably lower costs per piece and a consistently high quality. With its twin-spindle pick-up turning machine—VL 1 TWIN—EMAG has developed a solution: It simultaneously machines two identical bevel gears at high speed within the same machining area. A robot cell and swivel table can easily load this machine. All this brings the cycle time down to 4.5 seconds.

The demand for all-wheel-drive vehicles is growing. In Germany, for instance, they now represent approximately 20 percent of new vehicle registrations. In other countries, such as Sweden and Switzerland, the figure is even higher. This development implies a sharp increase in the number of bevel gears produced, which is subject to a growing cost pressure as are all mass-produced workpieces in the automotive industry. The production process generally starts with a sophisticated forging procedure during which the component obtains its characteristic bevel gear teeth. This is followed by various turning processes: the taper face opposite the serration, a small offset on the taper face, the inner bore and the end face are all produced this way. Whether these processes are performed directly within the scope of a final hard machining operation or each component is first soft turned and then hard turned depends on the manufacturer's specific production solution. “Regardless, it’s about managing very large quantities cost-efficiently, quickly, and free of defects,” explains Daniele Loporchio, Technical Sales Manager at EMAG. “That is exactly why we designed the VL 1 TWIN. The machine is perfect for soft and hard machining of a wide variety of bevel gears up to 75 millimeters in diameter (3 in).”  

Cycle Time of just 20 Seconds

The basic principle of this pick-up turning center plays a decisive role. It features two pick-up spindles (9.9 kW/136 Nm at 40% duty cycle) that are used to always machine two identical bevel gears in parallel at high speed (OP 10 – OP 10). The two spindles load and unload the machining area in just five to six seconds. The machining steps described above are then performed successively and in a single clamping operation with a total cycle time of about 25 to 40 seconds (depending on type and size of part). The average chip-to-chip time is just under six seconds. A special clamping solution reproduces the negative image of the component’s gearing and holds it firmly in place for the entire time. Additionally, the VL 1 TWIN is able to drill into solid material, which is how the bevel gear’s center bore is produced.  

This machines whole approach leads to fast production and high output quantities, while significantly reducing the price per spindle with rigorous cost controls – contributing to the low unit costs.

Focus on Component Quality

With EMAG equipment, there are a range of standard features that ensure component quality and reliability. For instance, the VL 1 TWIN has a machine base made of MINERALIT®, which significantly reduces vibrations during the turning process, leading to longer tool life and lower tool costs. Headstocks can traverse autonomously, allowing the diameter and length (X/Z directions) of both components to be adjusted independently of one another if there any deviations, e.g., following the change of an indexable insert. The wear-free linear drive in the X-axis, including the direct distance measuring systems, is equally important. It has an acceleration of 8 m/s2 (1,575 fpm) with precise long-term accuracy. The roller guides in all linear axes guarantee further precision.

Loading the VL 1 TWIN with a Robot

EMAG develops the actual production task for the bevel gear including its automation and interlinking in a very flexible manner and adapts it to the customer's needs. The technical starting point of the parts flow is the integrated pick-up automation system, which is responsible for the flow of parts within the machine. In order to increase the production volume, EMAG's developers can combine the VL 1 TWIN with a powerful robot cell and a swivel table. In this case, the gripper is precisely adapted to the shape of the component. Pre-positioned component containers simplify transport as well as loading and unloading. This allows the cycle time to drop all the way to 4.5 seconds and individual process flows are easily reproducible. Additional processes, such as measuring, marking and cleaning, can be integrated in the same cycle time. 

In addition to this, two VL 1 TWINs can be loaded with the robot cell mentioned earlier or with EMAG's TrackMotion automation system (OP 10 – OP 10, OP 10 – OP 10). In the latter case, the TransLift (a lifting and rotating device with an electric gripper) picks up raw parts from a feeding conveyor and transports them to the machines. Both machines are loaded very quickly—a solution for four spindles that is both powerful and very compact.   

Relevant for Electric Drives

Low investment and production costs, short cycle times and high process reliability—provide a base that allow machinery manufacturers to feel equipped to produce bevel gears. “From classic combustion engines to purely electric drives, differentials remain relevant regardless of drive type. Whoever wants to modernize their production now and prepare for growing unit volumes definitely ought to take a closer look at this technology,” concludes Loporchio emphatically. “We’re convinced that the VL 1 TWIN is an ideal solution for many bevel gear manufacturers.”

  • Follow @CNCTimes

Captcha is required.
Sorry Captcha Unsuccessful!!

Latest News

  • 18 January, 2021

    POWER SKIVING HIGH QUALITY, PRODUCTIVITY AND COST EFFICIENCY IN GEAR CUTTING

  • 18 January, 2021

    Higher Precision Tool Gripping with New TungHold ER Rubber Sealed Spring Collets

  • 18 January, 2021

    Introducing the World’s First CIP Safety Over Ethernet/IP Safety Light Curtain

  • 18 January, 2021

    Emerson Introduces Advanced Redundant Control System-ARCS;for Increased Operational Certainty in Emergency Shut Down Situations

  • 18 January, 2021

    Kurt Introduces Revolutionary New Robotic Gripper

  • 18 January, 2021

    Accelerated Efficiency with Data-Driven Design:NEMETSCHEK Group

  • 18 January, 2021

    Nikon Metrology's new Detector Evaluation Package in accordance with ASTM E2737

  • 18 January, 2021

    Turning inserts and grades for steel from Sandvik :GC4425 and GC4415

  • 18 January, 2021

    TRUMPF Venture invests in two AI/ML-powered cyber security start-ups

  • 12 January, 2021

    PCB industry embraces Han’s Elfin cobot solution for loading and unloading

  • 12 January, 2021

    Remote engineering at Walter

  • 12 January, 2021

    FARO® ZONE 3D 2021 SOFTWARE RELEASED FOR OPTIMAL FORENSIC SCENE DOCUMENTATION

  • 12 January, 2021

    DIGITAL CLAMPING ADJUSTMENT DURING PRODUCTION PROCESSES

  • 12 January, 2021

    Mastercam Announces New Optimized 5-axis Post Processor for FANUC CNCs

  • 12 January, 2021

    OPEN MIND Presents hyperMILL® 2021.1

  • 12 January, 2021

    MACHINE CHECK OF THE MAGAZINE FERTIGUNG: VGRIND 340S -Rated very Good

  • 05 January, 2021

    Launch of new additive manufacturing venture Shape-3D.

  • 05 January, 2021

    TT3005, TT3010 and TT3020 Grades Expands to Positive Insert Line

  • 05 January, 2021

    FARO® LAUNCHES LATEST VANTAGE LASER TRACKER 6DOF PROBE

  • 05 January, 2021

    DIGITIZATION IN PROJECT PLANNING AND EXECUTION : FFG

  • 05 January, 2021

    Okuma's MCR-S (Super) Double-Column Machining Center Receives a 50th Machine Design Award

Previous Next

Related News

  • 29 December, 2020

    Automated 3D printing in boatbuilding

    Category: Mechatronics
  • 29 December, 2020

    New LightScene EV-110 and EV-115 by Epson

    Category: Mechatronics
  • 29 December, 2020

    Doosan Machine Tools Launches VCF 5500L to Expand Lineup of Multi-Purpose Moving-Column Vertical Machining Centers

    Category: Machine Tools
  • 22 December, 2020

    Rockwell Automation Simplifies Installation and Troubleshooting with Smart Guard Locking Switch

    Category: Mechatronics
  • 16 December, 2020

    Launching of BM 3540P for Large Plate Manufacturing in the LCD/Semiconductor Industry

    Category: Machine Tools
  • 15 December, 2020

    Truventor Announces Strategic Acquisition of Chizel.io.

    Category: Machine Tools
  • 15 December, 2020

    Upcoming and on demand webinars

    Category: Machine Tools
  • 15 December, 2020

    Epson’s Next-Generation LightScene Laser Projectors Unleash Dynamic

    Category: Mechatronics

Case Studies

  • 16 December, 2019

    Khodiyar Industries Chose ZW3D to Speed up Packaging Machine Production

    Category: Machine Tools
  • 01 April, 2019

    Why The World's Third Largest Motorcycle Manufacturer Opted For Universal Robots

    Category: Mechatronics
  • 29 March, 2019

    Aerospace: Sogeti - Additive Manufacturing for the new A350 XWB

    Category: Machine Tools
  • 11 March, 2019

    INTECH DMLS Achieves 27% Weight Reduction in 3D Printed Satellite Component using Altair InspireTM and OptiStructTM

    Category: Machine Tools
  • 25 December, 2018

    Renishaw and Hartford combine to deliver intelligent, ‘smart factory’ solutions

    Category: Machine Tools
  • 10 April, 2018

    Capacity Ahead Of Demand Is Going To Be The Driving Factor For Growth: General Machine Tools

    Category: Machine Tools
  • 10 April, 2018

    Customer Support is Very Crucial for The Success: Padmavati Group

    Category: Machine Tools
  • 03 April, 2018

    HAAS moulds the future for Mechasoft through Reliability and Flexibility

    Category: Machine Tools
  • 22 March, 2018

    HAAS - Enabling Leonine Deliver Highly Precise, Highly Accurate, High Volume Components

    Category: Machine Tools
  • 13 March, 2018

    PAL Robotics integrates magnetic encoder technology into robots to achieve balance

    Category: Mechatronics
  • 20 December, 2017

    Renishaw AM technology helps Swinburne electric car to best-ever Formula SAE result

    Category: Machine Tools
  • 05 September, 2017

    Automation under control: BLUM NOVOTEST

    Category: Mechatronics

Interviews

  • 30 April, 2019

    CNCTimes in conversation with, Ankit Sahu, Director, Objectify Technologies Pvt. Ltd.

    Category: Machine Tools
  • 10 July, 2018

    Niraj Wanikar, M.D., CNCTimes P. Ltd. talks about Plant Manager – a revolutionary Production, Planning and Control software.

    Category: Machine Tools
  • 10 July, 2018

    Mr Cyril Pereira, MD, Reed Triune Exhibitions, talks about AMTEX 2018

    Category: Machine Tools
  • 10 July, 2018

    Mr. Benedikt Ruf, MD, GINDUMAC GmbH and Mr. Pankaj Patel, Country Manager, GINDUMAC GmbH share their views about AMTEX 2018 and the Indian Market

    Category: Machine Tools
  • 10 July, 2018

    HMB International is getting overwhelming response at AMTEX 2018: Mr Gopal Bali, Country Manager Sales, HMB International

    Category: Machine Tools
  • 10 July, 2018

    SLTL is a global leader in CNC laser services: Mr Maulik Patel, Business Development - International, SLTL Group

    Category: Machine Tools
  • 21 June, 2018

    Indian customers shower trust on HAAS, and Phillips has perpetually strived to make this a reality.

    Category: Machine Tools
  • 27 December, 2017

    The response from the customer's base in India is steadily growing: IMI Precision Engineering

    Category: Mechatronics
  • 18 December, 2017

    Quality should be the focus, not the price when buying a CNC machine: Global CNC Automation

    Category: Mechatronics
  • 18 December, 2017

    “Engimach helps you to reach the right audience.”:Macpower CNC

    Category: Machine Tools
  • 18 December, 2017

    ‘Engimach has developed a lot over the years’: Beckhoff Automation

    Category: Mechatronics
  • 11 December, 2017

    ‘Engimach is the best platform to showcase your products’ : Gravotech

    Category: Machine Tools

Product Showcase

  • 25 February, 2020

    Pressure Sensors with Display from BALLUFF

    Category: Mechatronics
  • 04 February, 2020

    HYPERTURN 65 Powermill – For Increased Productivity in Complex Complete Machining

    Category: Machine Tools
  • 08 December, 2019

    Electronica HiTech brings Latest Technology in CNC Wire CUT EDM- Model Job Master D zire

    Category: Machine Tools
  • 08 December, 2019

    Electronica HiTech brings CNC Vertical Machining Center MVP Series (Linear Guide Way) from Hartford

    Category: Machine Tools
  • 08 December, 2019

    Electronica HiTech offers you high speed, High Accuracy, Precision Machining Centers- TGV series from Hartford

    Category: Machine Tools
  • 08 December, 2019

    Electronica HiTech brings Centerless GrinderMachine- JHC 18 From Jainnher

    Category: Machine Tools
  • 08 December, 2019

    Electronica HiTech brings High-Rigidity & Heavy-Duty Cutting Horizontal Turning Center from Doosan Machine Tools

    Category: Machine Tools
  • 07 December, 2019

    Electronica HiTech brings High Productivity Gang type Global Compact Turning Center from Doosan Machine Tools

    Category: Machine Tools
  • 07 December, 2019

    ELTECH-D400 ZNC EDM from Electronica HiTech Machine Tool Pvt. Ltd

    Category: Machine Tools
  • 07 December, 2019

    Electronica HiTech deals with VMC that guarantees unmatched performance

    Category: Machine Tools
  • 06 December, 2019

    CNC Precision Grinding Machine from Tsugami G300/G350

    Category: Machine Tools
  • 06 December, 2019

    VA3 High Speed Vertical machining Center from Tsugami

    Category: Machine Tools

Technical Articles

  • 28 January, 2020

    The Additive Update: Wilson Tools

    Category: Machine Tools
  • 04 May, 2019

    Faster and better machining performance: on existing equipment

    Category: Machine Tools
  • 23 April, 2019

    The 3D FABRI GEAR Advantage

    Category: Machine Tools
  • 19 April, 2019

    Development of Two Types of Sintering Bonding Materials for Next-generation Power Modules

    Category: Machine Tools
  • 03 April, 2019

    Digital Twins, The Birth of Constant Optimization: Siemens

    Category: Mechatronics
  • 01 April, 2019

    Bridging the Skills Gap with MAZATROL

    Category: Mechatronics
  • 22 March, 2019

    THE PRECISE GEOMETRY OF 3D CUTTING KBM motors as a byword for accuracy in laser cutting

    Category: Machine Tools
  • 05 March, 2019

    Fire risks in a CNC

    Category: Machine Tools
  • 19 February, 2019

    Group Technology: Operational Excellence in the Industry 4.0 Era

    Category: Machine Tools
  • 30 June, 2018

    Robotic Fettling for Iron Castings- A revolution in the foundry industry

    Category: Mechatronics
  • 08 May, 2018

    Collaborative Robots, India and the Future of Manufacturing

    Category: Mechatronics
  • 13 June, 2017

    PRACTICAL APPROACH TO CONTROL WASTE IN MANUFACTURING

    Category: Machine Tools

Blogs

  • 19 April, 2019

    Additive Manufacturing: a big leap in production

    Category: Machine Tools
  • 11 July, 2018

    Advanced Machining with Industrial Robots.

    Category: Mechatronics
  • 14 August, 2017

    Industry 4.0 applications outside

    Category: Machine Tools
  • 01 August, 2017

    Industry 4.0: Applications in a shop

    Category: Machine Tools
  • 19 July, 2017

    Industry 4.0 – Machine monitoring

    Category: Machine Tools
  • 24 May, 2017

    Achieving tolerance less than the accuracy: CNC

    Category: Machine Tools
  • 17 May, 2017

    Key parts of a CNC fixture

    Category: Machine Tools
  • 09 May, 2017

    Mohs scale and cutting tools

    Category: Machine Tools
  • 10 April, 2017

    Epoxy granite beds in CNCs

    Category: Machine Tools
  • 25 March, 2017

    Industry 4.0 demystified

    Category: Machine Tools
  • 17 February, 2017

    The CNC teaching gap in the industry

    Category: Machine Tools
  • 02 December, 2016

    Exact stop check in Milling

    Category: Machine Tools

Videos

  • 03rd September, 2020

    ABB offers Augmented Reality on a smartphone to simplify robot installations

    Category: Mechatronics
  • 21st July, 2020

    Offline Programming For Press Brakes & Full 3D Simulation For Sheet Metal Bending

    Category: Machine Tools
  • 20th July, 2020

    Bill of Materials in WORKPLAN

    Category: Machine Tools
  • 07th July, 2020

    Sales order creation in WORKPLAN

    Category: Machine Tools
  • 07th July, 2020

    Online Event Teaser | Die & Mould - Make it Smarter!

    Category: Machine Tools
  • 01st July, 2020

    DESIGNER: Direct Modelling CAD software.

    Category: Machine Tools
  • 04th May, 2020

    CAM Software 3D Mold Part SolidCAM iMachining

    Category: Machine Tools
  • 04th May, 2020

    SolidCAM Car wheels CNC Machining 5 Axis

    Category: Machine Tools
  • 04th May, 2020

    SolidCAM Mill Turn & iMachining on OKUMA Multus BII series

    Category: Machine Tools
  • 04th May, 2020

    SolidCAM Advanced Mill Turn on a Citizen D25 CNC with Iscar

    Category: Machine Tools
  • 30th April, 2020

    5 axis laser cutting process by Radmax

    Category: Machine Tools
  • 21st April, 2020

    Check out how easily you can create the quotation in WORKPLAN for existing opportunity.

    Category: Machine Tools

Inventory

  • 17 July, 2019

    2001 MORI SEIKI ZT2500Y 4-AXIS TWIN SPINDLE TWIN TURRET CNC LATHE W/ LIVE MILLING AND BAR FEED

    Category: Machine Tools
  • 17 July, 2019

    2010 OKUMA B-300W CNC Lathes

    Category: Machine Tools
  • 17 July, 2019

    2004 Gildemeister Twin 42 CNC Lathe with Siemens Control

    Category: Machine Tools
  • 17 July, 2019

    2005 DOOSAN/DAEWOO PUMA 2500 LSY MULTI AXIS MILL & TURN CENTER/LATHE

    Category: Machine Tools
  • 17 July, 2019

    2013 MORI SEIKI NMV5000 DCG 5-Axis CNC Vertical Machining Center

    Category: Machine Tools
  • 17 July, 2019

    2000 WALDRICH COBURG MULTITEC 2500 AP CNC PORTAL MACHINING CENTER

    Category: Machine Tools
  • 17 July, 2019

    2005 MORI SEIKI MT 2500SZ/1500 TWIN SPINDLE CNC MILLING / TURNING CENTER

    Category: Machine Tools
  • 17 July, 2019

    2013 Mazak Integrex e-670H II 4000U 5-Axis Multi-Tasking CNC Turning & Milling Center

    Category: Machine Tools
  • 17 July, 2019

    2006 MAZAK Integrex IG 300 IV ST CNC Turning/Milling Center

    Category: Machine Tools
  • 17 July, 2019

    2009 HAAS SL-20T CNC 2-AXIS TURNING CENTER LATHE W/EPSON 6-AXIS MATERIAL HANDLING ROBOT

    Category: Machine Tools
  • 17 July, 2019

    2014 DMG NT6600 DCG CS X 6000 Turning Milling Centre.

    Category: Machine Tools
  • 17 July, 2019

    2008 MORI SEIKI NT4200/1000SZ DCG 5-AXIS CNC MILLING AND TURNING CENTER W/ GANTRY LOADER

    Category: Machine Tools

Showroom

  • 31 March, 2020

    MJP 2500-IC

    Category: Machine Tools
  • 09 October, 2019

    joanna Wong

    Category: Machine Tools
  • 28 November, 2018

    Polycarbonate Roof Sheet Manufacturers

    Category: Machine Tools
  • 28 November, 2018

    Industrial Exhaust Fans Manufacturers

    Category: Machine Tools
  • 17 November, 2018

    DMU -50 DMG GERMANY

    Category: Machine Tools
  • 17 May, 2018

    201

    Category: Machine Tools
  • 22 December, 2017

    Ul-

    Category: Machine Tools
  • 06 May, 2017

    LSV-2050

    Category: Machine Tools
  • 06 May, 2017

    GST - 55 TO LST - 525

    Category: Machine Tools
  • 08 April, 2017

    tecnicrafts

    Category: Machine Tools
  • 08 April, 2017

    Nakanishi

    Category: Machine Tools
  • 08 April, 2017

    PCM Willen S. A.

    Category: Machine Tools

TESTIMONIALS VIEW MORE

We would like to express our sincere appreciation for your service to us.You have provided us best marketing platform through CNCTimes. We look forward to extending our contract with you for years to ...

Mr.Adil Atar, Ass.Mng.Technical Sales & Service: Precision Machinekraft

Dedication and determination is key to success and CNC Times team is evident to it - FARO Business Technologies (I) Pvt Ltd

Ms. Amrita Gokhale , FARO Business Technologies

Seminar was really very good, please let us know about future seminars. we would like to attend the seminar on "Machining of the material above 60 HRc like titanum"

Roshan Deshmukh, Design Engineer - Ashvini Magnets Private Limited

FOLLOW US

TECHNOLOGY FOCUS

    Machine Tools

    • CNC Lathe
    • Boring Machines
    • Drilling Machines
    • Spark Erosion
    • Wire Cut
    • Vertical Machining Centers - VMC
    • Horizontal Machining Centers - HMC
    • Grinding Machines
    • Gear Cutting Machines
    • Additive Manufacturing - RP
    • Multi-Axis Machines
    • Multi-Tasking Machines
    • Welding Machines
    • Presses
    • Laser Cutting
    • Others
    • IIoT

    Metrology

    • CMM
    • VMM ( Vision Measuring Machines )
    • PCMM ( Portable CMM )
    • Measuring Instruments
    • Probing Technology
    • 3D Scanners
    • Roundness Measurement
    • Surface Roughness Measurement
    • Contour Measuring Machines
    • Others

    Accessories

    • Workholding
    • Toolholders
    • Spindles
    • Coolants
    • Others

    Software

    • CAD
    • CAM
    • CAE
    • ERP
    • Inspection Software
    • Reverse Engineering Software
    • MES
    • Others

    Mechatronics

    • Robotics
    • Automation
    • CNC Controllers
    • Others

    Cutting Tools

    • Turning Tools
    • Milling Tools
    • Grinding Wheels
    • Drilling
    • Others

INDUSTRY VERTICALS

  • General
  • Automotive
  • Aerospace
  • Healthcare
  • Healthcare Engineering
  • FMCG
  • Consumer Durable
  • Defence
  • Electronics
  • Oil & Gas
  • Heritage
  • Heavy Engineering
  • Die & Mold
  • Plastic
  • Footwear
  • Jobshop

POLICIES

  • Payment Policy
  • Terms of Use

PROFILE

  • About us
© 2021 www.cnctimes.com
Developed & Maintained by CNCTimes.com