Production Machining

JUL 2013

Production Machining - Your access to the precision machining industrial buyer.

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VERTICAL TURNING that is being used more often, both in the small batch and the mass production of hardened workpieces. Te hard turning process ofers equivalent surface fnishes and allows for the process chain to be shortened by eliminating the grinding process. Also, turning machines are less expensive than grinders, and their energy consumption is lower. Unlike the grinding process, hard turning can often be carried out dry, which is more environmentally friendly. Unlike the grinding process, hard turning can often be carried out dry, which is more environmentally friendly. Inverted Design for Hard Turning Te VL 5 is specifcally designed for hard turning heat-treated workpieces. Its features make it capable of handling the heavy stresses during hard turning. Te machine's base is constructed of Mineralit, a polymer concrete with a vibra:: The design of inverted vertical turning centers requires a small footprint on the shop foor. Self-contained automation, including a pick-and-place conveyor, are integral to the machine tool. tion resistance 8× better than cast iron. Stability is critical for hard turning because any chatter generated in the turning process transfers to the workpiece. "A vibration-resistant machine leads to an improved surface fnish on all workpieces it machines, which also leads to an improvement in tool life," says Peter Loetzner, CEO, Emag. Te machine's work spindle and workpiece are located above the tool, which ofers ideal chip fow conditions as the material is removed from the machine by a chip conveyor. All of the machine's guideways are located above and away from the machining zone, keeping them clear from chips or dirt. Tis increases the component accuracy and reduces the maintenance efort, the company says. Te machine has the ability to include integral automation and uses a conveyor belt with prisms that hold the raw parts in place. Te conveyor belt moves the workpieces directly into the pick-up station, where they are picked up by the work spindle and then machined. Workpiece changeovers are fast—the distance traveled between the loading and machining position is only 550 mm. Tis shortens the time between machining processes. In the Real World One shop uses the VL 5 to produce gears for an automotive industry sub-supplier. Te machine produces a total of eight diferent gears for a dual-clutch transmission system. Following the hardening process, the workpieces are pre-turned on the machine to remove the hardened top layer, then a synchronous ring is welded onto the workpiece away from the vertical turning center. Te workpiece is then returned to the machine and fnish-turned. Before this shop had the vertical lathes, comparable operations were performed on grinders. "Tis company started investing in machines for their hard turning process as an alternative to grinding, because the investment costs were so much lower," Mr. Loetzner says. Also, the machine leaves the workpieces with an amazing surface fnish, according to the company. "Hard turning on the VL 5 is in no way inferior to the old grinding process, and the machining times are noticeably shorter," he says. 34 PRODUCTION MACHINING :: JULY 2013

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