EMAG VT 4-4 inverted lathe: new concept for efficient machining of shaft parts

“The development of the market has led to more intense market competition.” This can be said to be the most appropriate description of the development of suppliers in the automotive sector. According to a survey conducted by Roland Berger Management Consulting Co., Ltd., the growth rate of the automotive market in the next two years is about 6%. But the rise of emerging markets has also brought more competitors to the original suppliers. How to deal with this phenomenon? First of all, as a matter of urgency, these suppliers must recognize market conditions and strive to improve their productivity and increase profit margins. To achieve faster pace, higher efficiency, more sophisticated products, and more economical production. So what kind of production solution can meet the above requirements? The VT 4-4, a new inverted shaft-type lathe developed by EMAG, the world's leading machine tool manufacturer, provides the best answer. The lathe can produce high-volume gearbox parts with the highest efficiency.

The production of drive shafts and gear shafts can be said to represent a very critical part of the automotive manufacturing process. Many of these components have very precise and complex geometries and play a special role in the process of use. For example, high-precision gears ensure efficient torque transmission in the transmission, while high-precision shoulders and slots ensure a secure connection of components. It can be said that the overall efficiency of the powertrain depends to a large extent on the functionality of these shaft components. Therefore, automotive suppliers must have the ability to quickly and accurately mass produce these highly complex components. Moreover, it is necessary to ensure that the shaft parts produced have perfect geometric shapes and are most likely to meet the requirements of the finished product. Because for automotive designers, they can accept tolerances of only a few microns.

How can we do this? Machine tool expert EMAG has been committed to the research and development of lathe technology for decades. Innovative shaft machining technology solution - four-axis inverted shaft lathe VT 4-4, opened a new chapter in the field of machine tool processing. The lathe can process components up to 1050 mm long and 200 mm in diameter:

Synchronization: 4-axis simultaneous machining with a maximum speed of 4500 rpm. Equipped with two turrets, each with 12 tool positions, equipped with a turning tool and a power tool (one of which is reserved for the workpiece holder).

Automation: The workpiece holder moves the blank into the processing area and removes the finished part after processing. While one workpiece holder feeds a new workpiece to the lathe, the other workpiece holder removes the finished workpiece.

Ensure a low cost per piece

“This principle brings many benefits to the production of shafts – especially in mass production.” Dr. Guido Hegener, General Manager of EMAG Salah Machine Tool GmbH, Germany, explains, “The workpiece change of the VT 4-4 lathe” Fast time, short production cycle, and simple automation system integrated to minimize the production cost of a single product.” In standard operation, the VT 4-4 lathe is equipped with two compact, space-consuming Very small conveyor belts capable of accommodating 28 blanks and 28 finished components respectively. Moreover, a plurality of VT inverted lathes can be connected to each other in a low-cost and high-efficiency manner by a conveyor and a reversing unit or a robot.

Focus on product quality

EMAG engineers pay particular attention to the quality of the products they produce when developing production equipment. The bed of the VT series of inverted lathes is cast from the high-grade mineral material MINERALIT®. The lathe is modular in configuration: a powerful machining spindle, turret and tailstock. The sturdy and rugged body of the lathe ensures vibration disturbance during lathe machining, ensuring high quality machined surfaces and precise geometry. EMAG's unique inverted layout ensures long-lasting process reliability, and the smooth chipping environment avoids chip build-up in the processing area.

“At the same time, we also pay great attention to the convenience of the lathe operation process.” Dr. Guido Hegener stressed: “After all, people are very important factors in the production process. Whether it is operation or maintenance, we all hope that the lathe is for the operator. It's quick and easy. To achieve this, all the relevant components of the VT series lathes – from electrical to hydraulic and cooling systems – are easily accessible and come with an intuitive operator interface.

Technology determines the future

The VT 4-4 lathe provides an efficient production solution for the production of gearbox parts. But whether it is short production cycle, high flexibility, compact structure, small footprint, or integrated automation technology, such a new processing concept embodied in the VT 4-4 lathe can be recognized by customers and eventually win the market. ? Dr. Guido Hegener said with confidence: "We are extremely optimistic about the development of the inverted shaft type lathe. The VT 4-4 lathe has excellent cost performance and subtly complements the EMAG Group's vertical shaft machining machine series. We believe that the VT 4-4 inverted lathe will definitely stand out in the market."

Technical Parameters

Dr. Guido Hegener, General Manager of EMAG Machine Tool Co., Ltd.

The VT 4-4 four-axis inverted lathe can machine shaft workpieces up to 1050 mm and with a maximum diameter of 200 mm.

VT 4-4 four-axis inverted lathe for mass production of gear shafts

The VT 4-4 four-axis inverted car automatically feeds and unloads the workpiece through the turret, while transferring the workpiece using the conveyor belts on the left and right sides of the lathe.

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