openPR Logo
Press release

Joint “attack” on the camshaft

05-21-2012 07:12 PM CET | Industry, Real Estate & Construction

Press release from: EMAG Holding GmbH

EMAG VTC 315 DS - Machining of camshaft

EMAG VTC 315 DS - Machining of camshaft

For example in China – even if the automobile market in the country is currently growing more moderately, the “Middle Kingdom” is still the driving force on the global market. Around 11 million automobiles were produced in China in 2009 and the figure rose to around 14 million in 2010. In 2011, production growth slowed to about 15 million vehicles (source: PwC, Statista). Imports of automobile components, complete engines and gear boxes are also increasing rapidly. On a global scale, according to the foreign trade experts from Germany Trade and Invest, China is already the third largest importer. How can these rates of increase be managed using economical and high quality processes, both at established production locations outside China and also when planning new production plants?

Crankshaft and camshaft machining – a prime example

The production of crankshafts and camshafts are a prime example because both components are at the heart of engine production and their extraordinary geometry demands complex production processes. Grinding has a special role to play in the overall process because it must ensure that the components are true to size. At the same time, the process is often time-consuming and demanding – in particular, shafts which are very slim are not very strong in the machining direction which often means that sophisticated stabilization methods must be used with multiple trailing steady rests. Consequently, only comparatively low feed rates can be used – particularly to eliminate true running inaccuracies. This naturally results in long cycle times and low output. “We decided to tackle this problem head on in our development of a new grinding technology based on the vertical clamping of the component. Our idea was to reduce the forces which act on the component during the grinding process. Ultimately that will allow higher feed speeds,” explains Dr Guido Hegener, CEO of EMAG Salach Maschinenfabrik GmbH.

Low forces acting on the component

The development of synchronous support grinding, which is used on the VTC 315 DS vertical grinding machines, supplied by EMAG marks a breakthrough by developers in this sensitive application. The principle is based on the use of two grinding wheels which act on the crankshaft or camshaft from two sides moving in different directions. The normal forces which occur in the feed direction are compensated by the fact that the grinding wheels are mounted opposite each other and machine the component simultaneously. At the same time, a simple NC-controlled support is used to press against the workpiece from one side. This means that the workpiece cannot move in any direction and also eliminates tangential forces. “This design therefore has multiple positive effects,” says Guido Hegener. “On the one hand, extremely high feed speeds for grinding delicate workpieces such as a crankshaft or camshaft are possible due to the rigid clamping operation. On the other, two grinding wheels are used simultaneously. This drastically reduces the machining time compared to the conventional grinding processes in use today.”

Vertical design positive

The design principle of the EMAG grinding machine is another major factor in ensuring that the components can be ground at low cost. The shaft is clamped vertically inside the VTC 315 DS. The workpiece spindle is at the top, the tailstock is at the bottom. The entire grinding process on the shaft takes place in this position. The vertical position of the component also assists in producing good chip flow. This means that the removed material can be removed particularly easily and efficiently together with the cutting fluid. In addition, the cutting fluid does not flow over the structure of the machine and its temperature is not subject to fluctuation at any time during the process. “This is a point which ultimately has a direct bearing on machining quality because the whole subject of heat management in the system is insignificant,” says Guido Hegener. At the same time, the vertical design makes the system simpler to operate and ensures that the production process can be completed efficiently. Furthermore, there is generally no need for separate catching on the VTC 315 DS. This, in turn, simplifies the setting process.

4-cylinder camshafts with high true to size precision

What have been the experiences of users of the synchronous support grinding principle? “The response that we have had has been extremely positive,” says Guido Hegener. “The principle can also be used for transmission shafts, propeller shafts, pump shafts and compensating shafts with a maximum length of up to 600 millimeters. In every case, there has been a massive leap in productivity. In some cases, the machining time has been cut by up to 70 percent compared to traditional grinding.” On the other hand, the machining quality is improved. One example of this is the experience by a user in the production of a cast 4-cylinder camshaft for a car. The machining of the main bearing takes place in several sequences each with a grinding time of five seconds. Despite the short grinding time, true running inaccuracy levels of less than 10 mm have been recorded. This is much lower than the maximum tolerance limit and marks a clear improvement compared to the grinding process used in the past – in other words, a leap forward in quality.

Joint attack on the camshaft

Synchronous support grinding is not just appropriate for circular grinding but also produces positive effects for non-circular applications. Pairs of cams on 4-cylinder camshafts can be machined simultaneously which means that four grinding wheels can grind a single camshaft at the same time. This process on the one hand results in drastic reductions in machining times while on the other increasing the quality of the cam shape. This produces double benefits for the user.
This machining process means that EMAG can now complete the entire process chain for a camshaft comprising end machining, turning, deep hole drilling, milling, circular grinding and non-circular grinding with vertical clamping.

Major market opportunities

The fact that the management team at EMAG believes that this process has major opportunities on the market will certainly not come as a surprise. But there are a whole host of other arguments in favor of synchronous support grinding including the fact that the much shorter machining times also mean considerably lower energy costs. “The energy per piece cost is much lower. This also means lower costs for the user,” confirms Guido Hegener. Furthermore, there is the fact that the vertical systems require less space than machines with a horizontal design. “Economical processes, simple handling, high quality – the many benefits of synchronous support grinding compared to traditional grinding process will quickly become established on the market,” says Guido Hegener with a great deal of confidence.

The EMAG Group products cover the entire spectrum of machining processes in the metal working industry. Whether chucked, shaft-type or cubic components − the companies under the EMAG umbrella offer the best manufacturing solution for every customer. With its variety of technology centers EMAG has become an important partner in the realization of complete process streams for the manufacture of transmission, engine and chassis components.

EMAG Holding GmbH
Austrasse 24
73084 Salach
Germany

Tel: +49 / 7162 / 17-0
Fax: +49 / 7162 / 17-199
Contact person
Mr. Oliver Hagenlocher
Press and publishers
Tel: +49 / 7162 / 17-267
Fax: +49 / 7162 / 17-199
ohagenlocher@emag.com
www.emag.com

This release was published on openPR.

Permanent link to this press release:

Copy
Please set a link in the press area of your homepage to this press release on openPR. openPR disclaims liability for any content contained in this release.

You can edit or delete your press release Joint “attack” on the camshaft here

News-ID: 221725 • Views: 1340

More Releases for VTC

Asia-Pacific is the largest Internet Protocol Television (IPTV) Subscriber Marke …
Internet Protocol Television (IPTV) is a system which includes transmission of multimedia services over an Internet Protocol (IP) network instead of a traditional satellite. In other words, IPTV is a method of distributing multimedia services to the user’s location using IP suite over a packet-switched network, such as internet or local area network (LAN). IPTV works on television, with a set top box connected to the internet, which accesses channels
TeleMental Health Institute Forms Affiliate Alliance with Virtual Therapy Connec …
18 August 2016, San Diego, CA The TeleMental Health Institute (TMHI) is pleased to announce its strategic partnership with Virtual Therapy Connect (VTC). VTC offers a secure video connection platform, allowing practitioners and clients to connect remotely utilizing the computers, tablets, and smartphones they already own.. Through an affiliation with TMHI, VTC is encouraging its behavioral health professionals to obtain professional training from the industry’s leader, while also
21st Century Textile Industry Offers New Challenges and Opportunities
The 21st century brings Asia to the forefront. The worldwide currency fluctuations, the potentially huge market, the production of low labor costs all contribute to the shift of the textile and clothing industry to this region. In Hong Kong, SGS Hong Kong Ltd jointly hosted a seminar entitled ‘The Challenges and Opportunities of Fashion and Textile Industry in the 21st century’ along with the Vocational Training Council of Hong Kong (http://www.vtc.edu.hk/vtc/web/template/institute_desc_list.jsp?fldr_id=438).
VTC 6200-NI PC is suited for in-vehicle
NEXCOM’s popular VTC Series has been extended with the launch of VTC 6200-NI, a dedicated computing solution for in-vehicle surveillance applications. VTC 6200-NI utilizes the powerful video processing capability of the of Intel® Atom™ D510 processor which can support Dual Core technology. With additional Video Capture Module, VTC 6200-NI is the ideal solution for surveillance applications within public transport or fleet transport. Based on the Intel® Atom™ D510 Dual Core 1.66Ghz,
Telematics PC is ideal for Mobile Digital Signage Applications
The VTC 2100 telematics pc is a cost-effective solution for in-vehicle digital signage applications. Featuring the energy efficient Intel® Atom™ D410 1.6GHz processor, VTC 2100 will play most file formats (including video and crawling text) and can support dual display output. Specifically designed for in-vehicle operation, VTC 2100 can operate directly from a vehicles battery and can withstand the associated surges in power input. With exceptional resistance to
VTC 6200 PC is targeted at in-vehicle Surveillance applications.
With increased concerns over security threats, organizations around the world are re-considering their security requirements and investing in additional resources to enhance operations. With this in mind, Nexcom’s popular VTC series has been extended with the launch of VTC 6200, a dedicated computing solution for in-vehicle surveillance systems. VTC 6200 utilizes the powerful video processing capability of the Intel® Pineview D processor which supports Dual Core technology. With PC1 104