EMAG of­fers mul­ti­ple grind­ing solutions for trans­mis­sion shafts

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Tech­no­log­i­cal ad­vances in au­to­mo­tive en­gi­neer­ing are rapidly chang­ing the de­mand for pro­duc­tion tech­nol­ogy for new pro­cesses and the es­tab­lished pro­cesses like cylin­dri­cal or mod­u­lar grind­ing of trans­mis­sion shafts. Many com­po­nents, to meet the chang­ing needs, have com­plex geo­met­ric de­tails to be done with very high pre­ci­sion. Man­u­fac­tur­ing com­pa­nies de­pend on me­chan­i­cal en­gi­neer­ing firms like EMAG to de­velop in­di­vid­u­alised grind­ing solutions for the shafts – ide­ally, in­te­grated into com­plete pro­duc­tion lines. The grind­ing spe­cial­ists from the EMAG Group have de­vel­oped solutions like the HG 208 hor­i­zon­tal cylin­dri­cal grinder, which is ideal for the pre­ci­sion ma­chin­ing of shafts in se­ries pro­duc­tion. With its mod­u­lar de­sign prin­ci­ple, these ma­chines can be adapted to a wide va­ri­ety of ma­chin­ing tasks and in­te­grated into EMAG pro­duc­tion lines.

Off the shelf grind­ing solutions are vir­tu­ally im­pos­si­ble for many ap­pli­ca­tions. Drive shafts for elec­tric mo­tors, com­plex camshafts or crankshafts as well as trans­mis­sion shafts all re­quire very dif­fer­ent pro­cesses. Dif­fer­ent solutions are re­quired de­pend­ing on the nec­es­sary grind­ing op­er­a­tion – sin­gle, mul­ti­ple, par­al­lel or com­bined in­ter­nal and ex­ter­nal. The com­po­nent and ap­plied grind­ing tech­nol­ogy may de­mand tech­nolo­gies like in-process mea­sur­ing de­vices, dress­ing units for CBN and corun­dum grind­ing wheels, au­to­matic bal­anc­ing units and more.

“It is these very dif­fer­ent de­mands that char­ac­terise the de­vel­op­ment of the HG 208 hor­i­zon­tal cylin­dri­cal grinder,” Guido He­gener, Man­ag­ing Di­rec­tor of EMAG Maschi­nen­fab­rik, head­quar­tered in Salach, Ger­many. “We of­fer our cus­tomers a wide range of dif­fer­ent tech­nol­ogy mod­ules that can be eas­ily in­te­grated into a stan­dard­ised ma­chine. The HG 208 can be equipped with 1 or 2 com­pound slides, on each of which dif­fer­ent ex­ter­nal and in­ter­nal grind­ing spin­dles can be fit­ted. By us­ing a B-axis or a cen­tre drive, we can pro­vide the per­fect so­lu­tion for each cus­tomer-spe­cific ap­pli­ca­tion,” he added.

Vari­able trans­mis­sion

Con­tin­u­ously vari­able trans­mis­sion (CVT) vin­di­cates how de­vel­op­ments in the au­to­mo­tive in­dus­try can in­flu­ence and drive for­ward flex­i­ble man­u­fac­tur­ing con­cepts. This tech­nol­ogy is be­ing used in mod­ern hy­brid drives, ef­fec­tively com­bin­ing the power of com­bus­tion en­gines and elec­tric mo­tors. The cen­tral or pri­mary CVT shaft rep­re­sents a real grind­ing chal­lenge in the pro­duc­tion process. On the one hand, the con­trol wheel sur­face is pre­cisely ma­chined by an an­gle plunge. On the other hand, ax­ial ball track grooves have to be ma­chined.

With EMAG, both pro­cesses are per­formed in a sin­gle clamp­ing op­er­a­tion to avoid reclamp­ing er­rors and to achieve in­creased pre­ci­sion. For ma­chin­ing the grooves, the grinder is equipped with a dress­able ce­ramic CBN grind­ing wheel. With its per­fect dress­ing sys­tem, the qual­ity of the ball track stays high.

For ma­chin­ing the ta­per face on the pri­mary shaft (and sim­i­lar sur­faces on other shafts) EMAG has re­cently ex­panded its HG mod­u­lar sys­tem: A corun­dum grind­ing wheel with a max­i­mum di­am­e­ter of 750 mm (29.5 inches) is used for this task. “This ex­am­ple il­lus­trates how we con­tin­u­ally adapt the ma­chine and the avail­able mod­ules to the con­di­tions im­posed by the var­i­ous com­po­nents. This al­lows us to cre­ate the per­fect tech­nol­ogy con­fig­u­ra­tion for the cus­tomer: a large corun­dum grind­ing wheel for ex­ter­nal ma­chin­ing and a small CBN grind­ing wheel for ma­chin­ing the grooves, ar­ranged on 2 separate slides with their separate dress­ing sys­tems. This en­sures that the re­quire­ments for qual­ity and cy­cle times are met,” he said.

EMAG pro­duc­tion lines

An­other im­por­tant fac­tor for pro­duc­tion plan­ners in the au­to­mo­tive in­dus­try is the holis­tic ap­proach from EMAG. The me­chan­i­cal en­gi­neer­ing com­pany masters all pro­cesses for soft and hard ma­chin­ing and has ex­ten­sive ex­pe­ri­ence in the es­tab­lish­ment of com­plete pro­duc­tion solutions. For ex­am­ple, a trans­mis­sion shaft is pre-pro­cessed on EMAG VTC ver­ti­cal turn­ing cen­tres and fin­ished on HG se­ries grinders. With the as­so­ci­ated line au­to­ma­tion, EMAG com­pletely adapts it­self to cus­tomer re­quire­ments.

“The HG 208 has been on the mar­ket for around 15 years al­ready – this means cus­tomer’s ben­e­fit from a tech­nol­ogy that is well es­tab­lished, but which con­tin­ues to in­tel­li­gently ex­pand to cover a va­ri­ety of fields of ap­pli­ca­tion,” He­gener said. With these up­dates, the HG 208 can suc­cess­fully per­form cylin­dri­cal grind­ing op­er­a­tions on crankshafts and camshafts. Par­al­lel ex­ter­nal and in­ter­nal ma­chin­ing of hollow shafts is also made pos­si­ble with this con­cept. For this pur­pose, there is a vari­ant of the HG 208 with a di­rect-driven cen­tre drive.

EMAG grind­ing ex­perts see a great op­por­tu­nity in the grow­ing elec­tric ve­hi­cle mar­ket for the HG 208 and its as­so­ci­ated prod­uct lines, due to its ef­fi­cient grind­ing op­er­a­tion of the cen­tral drive shaft for such ve­hi­cles.

EMAG’s HG 208

A grind­ing spin­dle for corun­dum grind­ing wheels up to 750 mil­lime­ters (29.5 inches) in di­am­e­ter

Guido He­gener, Man­ag­ing Di­rec­tor of EMAG Maschi­nen­fab­rik.

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