EMAG: The best solution for heavy-duty machining of train wheels

Is it possible to machine train wheels automatically and flexibly with just one machine? The answer given by many users is no. They believe that when machining train wheels, it is necessary to use multiple machine tools, with multiple stages of interrelated production processes, and the workpiece needs to be repeatedly clamped, which means that a large number of new workpieces need to be processed every time. Re-clamping work. As always, the EMAG Group has introduced the VLC 1200 multi-function machining center with a sensitive industry sense, making it possible to complete the complete machining of the train wheels on a single machine. In this process, the process of heavy-duty machining is significantly accelerated, the quality of the workpiece is significantly improved, and the entire production process is more flexible.

“Heavy-duty machining” covers a range of operations such as turning, drilling, high-efficiency milling, etc., but the basic conditions are the same: the workpiece is usually a large or heavy workpiece, and the high metal cutting rate requires excellent performance. The process needs to be considered in a large direction rather than focusing on fragmented details. The processing of train wheels also needs to comply with these harsh conditions. At present, many manufacturers are still using complex, interrelated multi-stage production processes, however, this process has great disadvantages. First of all, the machine starts up at a high cost. Due to the different workpiece sizes, it is necessary to restart all the machines on the entire processing chain each time the workpiece is changed. “In addition, the associated processing takes too long. But for processes that can be machined with a single machine, the machining speed is significantly faster without any transfer,” adds Markus Woitsch, manager of the application engineering business at EMAG.

Figure 1: Markus Woitsch, Manager, Application Engineering, EMAG Group

It is important to ensure that the process is accurate

In fact, EMAG has long-term experience in the processing of complex workpieces with a single machine tool, and has two magic weapons in heavy-duty machining of train wheels:

· The machine tool is loaded with the spindle, which is an integral part of its design.

· Multiple operations such as turning, drilling, milling, etc. on one machine, only one or two times. To this end, the VLC 1200 is equipped with a turning tool sensor, a milling spindle and a tool changer.

“Because the workpiece only needs to be clamped twice, it guarantees dimensional accuracy and maintains a first-class surface finish. Because the price of wheel blanks is very expensive, this correct process is especially important for heavy-duty machining of train wheels” . Markus Woitsch explained. At the same time, the quality control system is installed in the lathe, and the measuring probe performs real-time detection on the workpiece and the process - the accuracy is up to 2 micrometers, thereby greatly eliminating the error of the machining process.

Figure 2: VLC 1200 for machining train wheels

Design is the key to determining the success of a lathe

In the application, how many factors have the success of the vertical structure of the EMAG VLC 1200 machine? “The vertical structure does play an extremely important role,” Markus Woitsch affirmed. “The workpiece spindle is suspended vertically above the workpiece so that the chips can fall directly into the chip conveyor and thus output from the machine to prevent the workpiece. It is heated by contact with hot chips and can avoid contamination of the work spindle." Especially for heavy-duty machining processes with less manual labor and high automation, the advantages of this design become more and more obvious.

Figure 3: Turning of train wheels with HSK 100-F160 turning tools

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