The Sharp End

The Sharp End

Emag has recently introduced the HG 208 horizontal cylindrical grinder. It is a perfect solution for precision machining of shafts.

Technological advances in automotive engineering are rapidly changing the demands for production technology – this is not just for new processes, but also applies to established processes such as the cylindrical grinding of transmission shafts. The grinding specialists from the EMAG Group have developed the perfect solutions for this environment: the HG 208 horizontal cylindrical grinder, which is the perfect solution for precision machining of the shafts in series production.
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. “It is these very different demands that characterise the development of the HG 208 horizontal cylindrical grinder,” says Guido Hegener, MD, EMAG Maschinenfabrik headquartered in Salach, Germany. “We offer our customers a range of technology modules that can be integrated into a standardised machine. For instance, the HG 208 can be equipped with one or two 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.”

Customised for CVT Transmissions
CVT transmissions are an example of how developments in the automotive industry can drive forward such a flexible concept. The primary CVT transmission 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 in order to avoid reclamping errors and to achieve increased precision. For machining the grooves, the grinder is equipped with a dressable ceramic CBN grinding wheel.
For machining the taper face on the primary shaft, EMAG has expanded its HG modular system: A corundum grinding wheel with a maximum diameter of 750mm (29.5 inches) is used for this task. “This illustrates how we continually adapt the machine and the available modules to the conditions imposed by the 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 two separate slides with their separate dressing systems,” explains Hegener.

Complete Production Lines from EMAG
Another factor for production planners in the auto industry is the holistic approach from EMAG. The mechanical engineering company masters all processes for soft and hard machining and has 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 customers benefit from a technology that is well established, but which continues to intelligently expand in order to cover a variety of fields of application,” summarises Hegener.

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