BUSINESS UNIT TURNING
Turning machines for chucked and shaft parts
CONTENTS Turning machines for chucked parts VL Machines
S. 6
S. 10
S. 12
VSC Multi-Spindle
S. 14
Classic Machines
S. 16
VL Multi-Spindle VSC Machines
Turning machines for shaft parts VT Machines
S. 20
VT Line
S. 22
TURNING MACHINES FOR CHUCKED PARTS
VL MODULAR SOLUTIONS The VL Series vertical pick-up turning machines were specially developed for manufacturing precision chucked components. To cover as wide a range of parts as possible, the VL Series is available in four versions for a workpiece diameter ranging from 10 mm to 400 mm. Machine body Z-slide X-slide Spindle Measuring system (optional)
Turret (optional Y-axis) Automation
X
Z
(Y) C
0.3 SEC. TURRET SWIVELING TIME
X-AXIS RAPID TRAVERSE RATE 60 M/MIN
MAXIMUM PRECISION – DIRECT POSITION MEASURING SYSTEMS
THE PATENTED EMAG TURRET
+ Glass scales – Fully encapsulated linear
+ Fast, with zero play and wear – the EMAG turret is equipped
glass scales in all linear axes.
with a direct drive (torque motor) for swiveling.
+ Precise – Thermal stability is ensured thanks to an ambient temperature controlled cooling system.
+ Flexible – The turret has space for twelve tools (featuring either a VDI or BMT interface). Driven tools can be used in all tool stations. The optionally available Y-axis ensures maximum flexibility.
6
+ High strength
Large working spindle bearing diameter + MINERALIT® polymer concrete machine body
+ Complete automation
Including raw and finished parts storage areas
+ Simple handling
All the service units are easy to reach
THE VL PLATFORM I VL Machines
BENEFITS OF THE VL SERIES
+ Minimum footprint
Compact machine design
+ Maximum performance
Short distances between the machining area and pick-up automation system
+ Latest generation of control systems - Fanuc 32iB+ - Siemens Sinumerik ONE
Machines shown in trade show format (with optional decorative sheet kit)
7
VL MODULAR SOLUTIONS VL 2/VL 100 and VL 4/VL 200 for small and medium-sized workpieces The VL 2/VL 100 and VL 4/VL 200 pick-up turning machines are ideal for workpieces with a diameter up to 100/200 mm. They feature integrated automation and a parts storage area, which enables them to operate completely autonomously, relieving the strain on production personnel. Efficient mass production of varying batch sizes is possible and, thanks to flexible clamping systems, they can also easily machine whole part families.
Intermediate gear Machines: VL 2 Sawn part diameter: 60 mm Material: C45 2 OPs
Cover Machines: VL 2 Sawn part diameter: 100 mm Material: X5CrNi1810 2 OPs
Sprocket
54.6 SEC.
Machines: VL 2 Pre-forged part diameter: 50 mm Material: 16MnCr5 2 OPs
VL 2/VL 4
100.8 SEC.
35.4 SEC.
Workpieces Line cycle time
Main hub Machines: VL 4 Forged part diameter: 120 mm Material: 16MnCr5 2 OPs
8
100.2 SEC.
143.4 SEC.
Piston Machines: VL 4 Sawn part diameter: 100 mm Material: 46S20 2 OPs
DIE VL-PLATTFORM THE VL PLATFORM I IVL VLMachines 2, VL 4, VL 6, VL 8
VL 6/VL 300 and VL 8/VL 400 for large workpieces Machine larger workpieces, or achieve maximum flexibility in production with a VL 6/VL 300 and VL 8/ VL 400 pickup turning machines. Integrated conveyor belt makes loading the machines with heavy parts a breeze. Place parts on the conveyor belt by crane and the machine takes care of everything else.
Spur gear Machines: VL 8 External diameter: 320 mm Material: 16MnCr5 2 OPs
212 SEC.
Drive gear
Line cycle time
Chuck diameter Swing diameter Workpiece length, max. Travel distances, X/Y (optional)/Z Main spindle » Power rating, 40%/100% » Torque, 40%/100% » Speed, max. Turret » Turret tool positions
198.6 SEC.
VL 2/VL 100
VL 4/VL 200
VL 6/VL 300
VL 8/VL 400
mm
100
200
300
400
mm
160
260
400
500
mm
210
280
420
520
mm
150
200
250
300
mm
650/± 50/375
760/± 60/415
900/± 30/495
1.010/± 30/595
inch
4
inch
6.5
inch
19.5
16.5
8
30/± 2.3/16.5
15.5
15.5
11
6
27.5/± 2/15
12
10
8
inch inch
8
20.5
10
35.5/± 1/19.5
12
39.8/± 1/23.5
kW
Fanuc 15,7/13,9
Siemens 16,7/14,5
Fanuc 22,7/18
Siemens 24,1/18,1
Fanuc 41,1/28,5
Siemens Fanuc Siemens 43/31,6 47,6/34,6 48,8/37,7 58/42
64/46
65/51
Nm
77/59
74/55
256/202
243/183
491/340
462/340
826/600
776/600
1/min
6.000
6.000
4.500
4.500
3.100
3.100
2.850
2.850
hp
ft-lb
21/19
57/44
22/19
55/41
30/24
188/149
32/24
179/135
55/38
362/251
341/251
572/443
572/443
Quantity
12
12
12
12
» Revolutions of driven tools
1/min
9.600
9.600
9.600
6.000
» Torque of driven tools at 30%/100% duty cycle
ft-lb
Nm
44/33
44/33
44/33
40/30
m/min
60/30/30
60/15/30
60/15/30
60/15/30
Rapid-traverse rate, X/Y/Z Control
ipm
32/24
32/24
32/24
30/22
2,363/1,181/1,181
2,363/591/1,181
2,363/591/1,181
2,363/591/1,181
Fanuc 32iB+/ Sinumerik ONE
Fanuc 32iB+/ Sinumerik ONE
Fanuc 32iB+/ Sinumerik ONE
Fanuc 32iB+/ Sinumerik ONE
Machines shown in trade show format (with optional decorative sheet kit)
Workpiece diameter, max.
Machines: VL 6 Sawn part diameter: 220 mm Material: 42CrMo4 3 OPs
Workpieces
154.8 SEC.
TECHNICAL DATA
Housing
VL 6/VL 8
Machines: VL 6 Forged part diameter: 220 mm Material: 16MnCr5 2 OPs
9
VL MULTI-SPINDLE MACHINES – VL 3 DUO EMAG has extended the VL Series product range with the VL 3 DUO, a twin-spindle machine solution for the highly productive manufacturing of chucked parts up to 150 mm (6 inches) in diameter. The VL 3 DUO integrates all of the EMAG technological developments (including self-loading spindle, the TrackMotion automation system and the modular design of the machine) to create a highly productive manufacturing system with a minimum footprint. The latest generations of controllers from FANUC and Siemens enable easy operation of the machines.
HIGH-PERFORMANCE TURNING WITH THE VL 3 DUO The VL 3 DUO scores highly for heavy-duty machining due to its rigid machine design. High feed forces with a large cutting depth reduce the machining time. Standard spindle:
High torque spindle:
ap = 4.75 mm
ap = 8.5 mm
f =
0.4 mm/rev
f =
0.4 mm/rev
vc =
250 m/min
vc =
250 m/min
0.2 in
0.02 in/rev
1,000 in/min
0.3 in
0.02 in/rev
1,000 in/min
TECHNICAL DATA Workpiece diameter, max.
150
Swing diameter
mm
240
Chuck diameter, max.
mm
210
Workpiece length, max./option
mm
110/175
Travel distance, X/Y (optional)/Z
mm
505/±30/250
inch
6
inch
9
inch
8
inch inch
4/7
20/±1/10
» Power rating, 40%/100%
kW
Fanuc 17,9/15,5
» Torque, 40%/100%
Nm
144/98
1/min
5.000
5.000
» Power rating, 40%/100%
kW
Fanuc 31,5/28,1
Siemens 31,2/26,3
» Torque, 40%/100%
Nm
255/192
255/192
1/min
5.000
5.000
Main spindles (2x)
» Speed, max. High torque spindle – Option
» Speed, max. Turrets (2x) » Turret tool positions » Speed driven tools » Torque driven tools Rapid-traverse rate, X/Y/Z Control
10
VL 3 DUO/VL 150 DUO mm
hp
ft-lb
hp
ft-lb
24/21
106/72
42/37,7
188/142
Siemens 20/17,2 145/112
26,8/23
107/83
41,8/35,3 188/142
Qty 1/min Nm
12 9.600 44/33
m/min
60/30/30
ft-lb ipm
32/24
2,362/1,181/1,181
Fanuc 31iB/Sinumerik ONE
THE VL PLATFORM I VL 3 DUO
VL 3 DUO FOR DEMANDING TURNING WORK + Working spindle with 5,000 rpm/32 kW/255 Nm at 40% duty cycle
+ Sturdy mechanical design – spindle flange to DIN 55026, size 6
+ Motor spindle with DirectDrive for minimum
run-up times, maximum true running and diameter tolerances
+ Water-cooled motor spindle for maximum
20
90
15
60
10
30
5
Torque (Nm)
3.600
Speed (rpm)
6.000
25
120
5.400
30
150
4.800
35
180
4.200
40
210
3.000
45
240
2.400
50
270
1.800
300
600
Torque (Nm)
Highly productive machining of chucked parts with a diameter of up to 150 mm (6 inches) with minimum space requirements
Power (kW)
thermal stability
1.213 1.408
MACHINING AREA OF THE VL 3 DUO:
+ Maximum torque over large range of speeds
Power (kW)
40% ED
40% ED
100% ED
100% ED
Integrated automation
Pick-up working spindle for loading and unloading
Unique machine concept
Two working spindles and two high performance tool turrets with torque motor
Optimum accessibility
Short distance to the turrets and working spindle ensure optimum accessibility.
Maximum flexibility
Parts storage area for up to 400 workpieces and TrackMotion automation system for high speed part transport between the parts storage area and machining areas as well as for turning the workpieces
Minimum floor space requirement
24.5 m2 for the complete machine: VL 3 DUO + TrackMotion + parts storage area + chip conveyor
* Fully equipped machine including chip conveyor, TrackMotion and parts storage area for up to 400 workpieces (depending on the workpiece geometry)
Machines shown in trade show format (with optional decorative sheet kit)
Maximum precision
Machine base made of MINERALIT® polymer concrete, machine weight 10,000 kg, roller guides and direct position measuring systems in all axes
11
VSC CUSTOMIZED SOLUTIONS VSC – Multi-functional production centers Machining + automation + measuring: The machines of the VSC Series are configured for individual production requirements. Their patented design guarantees the shortest travel times between the pick-up station and the machining area, reducing idle times. The MINERALIT® polymer concrete machine base and the twin-wall construction have an excellent vibration damping effect. In addition, there is a consistently symmetrical slide and machine design for a closed power flow and thermally stable production. The hydrostatically mounted working spindle in the Z-axis ensures high part quality and long tool life during soft and hard machining.
Z
Energy container
Machine body made of MINERALIT® polymer concrete
Measuring station Automation
C
Hydrostatic guideway (standard) Working spindle
Pick-up station
Turret
12
The high-speed 12-station disk-type turret features very short swiveling times. Driven tools can be used on all twelve turret stations for drilling or milling operations. The EMAG turret gearbox combines high speeds with high capacity while requiring minimum floor space.
+ Very high speed
– Very short swiveling times – High speeds when using driven tools
THE VSC PLATFORM I VSC Machines
THE EMAG TURRET
+ Very high capacity
– Very small design with high torque
+ Very high precision
– Turret firmly embedded in the machine base = High rigidity – Very high degree of repeat accuracy when indexing from tool position to tool position
+ Very high availability
– Inured to collisions, owing to the use of torque motors – No raising of the turret for swiveling. This means that no chips or dirt can get into the turret.
VSC 250/ VSC 250 DUO
VSC 400/ VSC 400 DUO
VSC 450/ VSC 450 DUO
VSC 500/ VSC 500 DUO
Workpiece diameter, max.
mm
250
340
400
440
Chuck diameter, max.
mm
inch
315
12,5
400
460
500
Swing diameter
mm
330
420
520
520
Travel distance, X/Y (optional)/Z
mm
900/± 25/300
860/± 140/315
935/-/315
935/-/400
» Power rating, 40%/100%
kW
43/31,6
48,8/37,7
48,8/37,7
80/64,4
» Torque, 40%/100%
Nm
462/340
776/600
776/600
1.100/820
1/min
6.000
3.400
3.400
3.400
» Turret tool positions
Qty
12
12
12
12
» Speed driven tools
1/min
9.600
6.000
6.000
6.000
» Torque driven tools
Nm
44/33
75/54
75/54
75/54
m/min
45/30/30
45/30/30
45/-/30
45/-/30
inch
inch inch
10
13
35,5/± 1/12
14 16
16,5
34/± 5,5/12.5
16
18
21
37/-/12,5
17,5
20 21
37/-/16
Main spindle
» Speed, max.
hp
ft-lb
58/42
341/251
65/51
572/443
65/51
572/443
107/86
811/605
Turret
Rapid-traverse rate, X/Y/Z
ft-lb ipm
32/24
1,772/1,181/1,181
55/40
1,772/1,181/1,181
55/40
1,772/-/1,181
55/40
Machines shown in trade show format (with optional decorative sheet kit)
TECHNICAL DATA
1,772/-/1,181
13
VSC MULTI-SPINDLE MACHINES VSC DUO – the twin-spindle machine for sequential operations The VSC DUO principle offers a highly efficient solution for the machining of medium to large numbers of parts on a minimal footprint. The work areas are completely separated, allowing the axes to be programmed independently of each other. This makes it possible to achieve sequential operations in one machine.
14
Both turrets accommodate not only stationary turning tools but also driven drilling and milling tools. This allows for either identical or different operations to be carried out in the two spindles:
+ After the first set of operations have
been carried out on the workpiece, using the first spindle, the back of the component is machined in the second one; or the second spindle could be used to machine the workpiece in the same clamping position.
+ Two workpieces can also be machined with identical operational sequences.
Machines shown in trade show format (with optional decorative sheet kit)
VSC 250 DUO: Separate, extremely sturdy machine bodies (workspaces) made of MINERALIT® polymer concrete; the two overhead slides are independently programmable.
THE VSC PLATFORM I VSC multi-spindle machines
MACHINING
15
Classic MACHINES – MSC 5 DUO, HSC 1, USC 850 The efficient entry into precision manufacturing Classic machines combine maximum efficiency with the high quality you expect from EMAG. These machines focus on the essentials and offer an optimized range of functions for typical machining requirements. The base machine is purchased from selected partners and equipped by EMAG with proven process and machining technology, such as chucks and tools. You benefit from EMAG‘s worldwide service network and fast spare parts supply – the ideal choice for cost-efficient production without compromising on reliability.
TECHNICAL DATA
MSC 5 DUO
USC 850
HSC 1
Workpiece diameter, max.
mm
120
700
50/300
Swing diameter
mm
327
800
350
Turning length max.
mm
85
2.000
570
Travel distance, X/Y (optional)/Z
mm
130/-/145
380/-/2.200
198/± 50/570
kW
7,5/9 10/12
40,8/30
14,7/12
1/min
4.500
2.000
4.000
inch inch inch inch
4,5
12,9 3,5
5/5,5
27,5
31,5
78,7
15/86,6
2/12
14
22
8/± 2/22,5
Main spindle » Power rating (30 %/100 %) » Speed, max. Turret tool positions Rapid-traverse rate, X/Y/Z Control
16
hp
30/22
11/9
Qty
2x8
12
12
m/min
24/-/24
15/-/15
30/10/30
ipm
945/-/945
590/-/590
1.181/393/1.181
FANUC 0i-TF PLUS
FANUC 0i-TF PLUS
FANUC 0i-TF PLUS
The MSC 5 DUO is a twin-spindle CNC lathe engineered for high-performance batch production. With its innovative split-bed design, powerful spindles and fully integrated 3-axis gantry loader, this machine delivers exceptional precision, reliability and efficiency. Whether in automotive, hydraulics, pneumatics or medical component production, the MSC 5 DUO ensures faster cycle times, reduced downtime and superior machining results.
CLASSIC MACHINES I MSC 5 DUO, USC 850, HSC 1
MSC 5 DUO
USC 850 The USC 850 is a state-of-the-art universal lathe that has been specially developed for the precision and efficient machining of large turned parts. With its robust design, state-of-the-art control technology and excellent machining accuracy, it is ideal for use in the supplier industry, aviation and general mechanical engineering.
The HSC 1 is a compact, powerful CNC lathe for the economical machining of turned parts in two consecutive machining operations (OP 10 / OP 20). Equipped with main and counter spindles as well as a turret with driven tools, the machine enables turning, drilling and milling in a continuous production process - on a single machine. Automatic spindle transfer ensures high precision and efficient machining of both sides of the workpiece no manual reclamping required.
Machines shown in trade show format (with optional decorative sheet kit)
HSC 1
17
TURNING MACHINES FOR SHAFT PARTS
VT MODULAR SOLUTIONS Fast processes are required for machining large quantities of shafts. Both the machining process and the loading and unloading processes must be completed extremely quickly. The VT 2/VT 100 and VT 4/VT 200 machines are guaranteed to achieve the maximum performance you require. Four axes, short distances, and a powerful main spindle – these are the strengths of the VT Series. The full effect of these can be felt, in particular, when machining large quantities. A key factor is the machining of parts from two sides. This greatly reduces the machining time. Two tool turrets, each with eleven tool positions which can be equipped with turning tools or driven tools, ensure machine flexibility.
Turret 1 Working spindle with C-axis Turret 2 Tailstock Automation
THE BENEFITS + Ready for integration with the
TrackMotion automation system.
+ Reduced machining times due to four-axis machining
+ Shorter idle times with simultaneous
loading and unloading of components
+ Lower investment costs thanks to integrated automation
AUTOMATION SEQUENCE The gripper in turret 1 takes the workpiece from the raw parts storage area and transports it to the main spindle/tailstock. At the same time, the gripper in turret 2 takes the machined workpiece from the main spindle/tailstock, transports it to the finished parts storage area and deposits it there.
20
VERTICAL TURNING CENTER I VT Machines
THREE KEY SUCCESS FACTORS + Reduced machining times
due to four-axis machining
+ Shorter idle times
with simultaneous loading and unloading of components
+ Highly productive shaft manufacturing thanks to integrated automation
6
SEC.
WORKPIECE CHANGEOVER TIME
TECHNICAL DATA
VT 2/ VT 100
VT 4/ VT 200
Chuck diameter
mm
160
250
Swing diameter
mm
210
270
Workpiece diameter, max.
mm
100
200
Workpiece length, max.
mm
400
630
Travel distance, X/Y (optional)/Z
mm 332/±25/625 395/±25/810
inch inch inch inch
6
8 4
15
10 10 8
25
13/±1/24
15/±1/32
kW
30,1/23,9
32,4/26,4
Nm
144/112
246/200
1/min
6.000
4.500
kW
33,5/26,5
33,9/29,3
Nm
142/112
231/200
1/min
6.000
4.500
Main spindle (Fanuc) » Power rating, 40%/100% » Torque, 40%/100% » Speed, max.
hp
ft-lb
40/32
106/83
43/35
181/148
Main spindle (Siemens) » Power rating, 40%/100% » Torque, 40%/100% » Speed, max.
hp
ft-lb
Workpiece diameter, max.: 100 mm
Workpiece diameter, max.: 200 mm
Workpiece length, max.: 400 mm
Workpiece length, max.: 630 mm
105/83
2 x 11
Turret tool positions Rapid-traverse rate, X/Y/Z
45/35
(2 x 1 gripper)
m/min
30/15/30
45/39
170/148
2 x 11
(2 x 1 gripper)
30/15/30
ipm
1,181/591/1,181
1,181/591/1,181
Revolutions of driven tools, max. 1/min
12.000
9.600
Torque of driven tools, 30%/100%
20/16,5
44/33,1
Control
Nm
ft-lb
15/12
32/24
Fanuc 32iB/ Fanuc 32iB/ Sinumerik ONE Sinumerik ONE
Machines shown in trade show format (with optional decorative sheet kit)
inch
21
VT LINE Complete machining of shafts and shaft-shaped workpieces in a manufacturing cell, including automation. With standardized automation components, two or three machines from the VT series can be easily combined to form a manufacturing cell. The machine can be optimally configured for each machining step, resulting in a highly productive solution.
Shaft machining: Centring, drilling, end machining
22
Axle journal machining: Soft turning of the outer contour
VERTICAL TURNING CENTER I VT Line
Rotor shaft machining: Twist-free turning thanks to skiving
Machines shown in trade show format (with optional decorative sheet kit)
Component changeover: The finished component is removed and taken to its storage area. The new raw part is loaded (sequence from right to left).
23
All EMAG Locations
www.emag.com
336-1-EN/09.2025 · Printed in Germany · © Copyright EMAG · Subject to technical changes.
At Home All Over The World.