At present, the international automobile market is booming and the growth momentum is fierce. According to data from the US market research firm Polk, car sales in 2011 increased by 3% compared to 2010. Many auto and supplier companies have busy production tasks and the situation is booming. In the face of the orders that come one after another, on the one hand, the demand for parts of â€œfine productionâ€ (timely production) will rise sharply in a short period of time; on the other hand, it poses a serious challenge to how to control the quality of good parts. According to the economic operation of China's auto industry announced by the Ministry of Industry and Information Technology in 2012, the cumulative production of automobiles in the whole year of 2012 was 19,217,800 units, a year-on-year increase of 4.6%, and the sales of automobiles was 19.36 million units, a year-on-year increase of 4.3%. The growth rate of production and sales increased by 3.8 compared with 2011. And 1.8 percentage points. In the middle and late 2013, the sales performance of the automobile increased significantly.
Take China as an example: Although China's car market has slowed down in recent times, compared with other markets in the world, this â€œcentral countryâ€ still plays the leading role of the world economy. In 2009, China's car production was still 11 million, and its car production has increased to 14 million by 2010. Although growth has slowed in 2011, the total production of cars has still reached 15 million (source: PwC, Statista). At the same time, imports of car parts, engines or gearbox assemblies are also growing rapidly. . According to foreign trade experts from German trade and investment institutions, China has become the world's third largest importer. Faced with such rapid growth, people cannot help but ask how they should respond to economically efficient and high-quality production methods. How should production bases inside and outside China plan production to meet this growth demand?
An application example proves that by adopting the new structure of the machine tool process, it is not only easy to meet the above challenges, but also to promote the overall quality of the engine: This is the unprecedented crankshaft and camshaft innovative grinding machine. Synchronous support grinding technology developed by EMAG can increase the productivity of crankshaft and camshaft manufacturers by 70% â€“ a quantum leap.
Excellent example of crankshaft and camshaft machining
It is well known that the crankshaft and camshaft are the two core parts of the engine, and the production process is particularly complicated due to the particularity of their geometry and size. During the machining of these two parts, the grinding process has to occupy a special position in the entire processing chain because the size of the components must be guaranteed. In addition, grinding is time consuming and the precision is very demanding. Especially when machining slender shaft parts, because the rigidity of the workpiece in the machining direction is poor, it is often necessary to configure a plurality of center frames to stabilize the workpiece. Therefore, after the workpiece is stabilized, the feed during machining needs to be controlled to a small extent, especially when eliminating inaccurate real errors. The small feed, which means high beats and low output. â€œWe have done a lot of work on this issue when we are developing the vertical shaft grinding process. Our research and development idea is to minimize the external force applied to the workpiece during grinding. Only in this way can the feed be improvedâ€ Dr. Guido Hegener, CEO of EMAFA Salah Machine Tool Co., Ltd. explained.
Small external force applied to the workpiece
EMAG VTC 315 DS machine
The VTC 315 DS machine equipped with EMAG's newly developed synchronous support grinding technology marks a major breakthrough in the study of reducing the external force of the workpiece. The principle of this new technology is the use of two opposite grinding wheels, the grinding wheel running in the opposite direction when machining the crankshaft or camshaft. Since the grinding wheels are opposed to each other on both sides of the workpiece, the radial forces in the feed direction cancel each other during synchronous cutting. The machine is also equipped with an NC CNC support that supports one end of the workpiece so that the workpiece does not deviate from any direction and the tangential force is eliminated. "This design reflects good positive effects in many ways," Guido Hegener said. â€œOn the one hand, due to the rigidity of the workpiece clamping, extremely high feeds can be used when machining elongated workpieces such as camshafts or crankshafts ; on the other hand, two grinding wheels are simultaneously ground, so it is common today. Compared to the grinding process, the machining time is greatly shortened.
Advantages of the vertical structure
Production system for complete machining of camshafts: from soft machining to grinding, all use VTC machine platform
Improving the economics of processing is another design tenet emphasized by the EMAG grinding machine. When machining a shaft with VTC 315 DS, the workpiece is clamped vertically in the machine . The workpiece spindle (headstock) is placed above the machine and the tailstock is placed below. The workpiece is subjected to a full set of grinding in this state. Due to the vertical clamping of the workpiece, the chipping is ideal. The cutting fluid together with the iron filings can be sent out of the processing zone simply and efficiently. In addition, the cutting fluid does not flow through the fuselage, so the cutting fluid temperature does not fluctuate throughout the grinding process. â€œThis is also an important factor in determining the quality of the process because there is very little heat transfer in the equipment,â€ explains Guido Hegener. At the same time, due to the vertical structure, the machine tool is easy to operate and the production process is efficient. In addition, the VTC 315 DS machine eliminates the need for special end face drives, which simplifies the commissioning process.
4-cylinder engine camshaft with extremely high dimensional accuracy
What are the experiences of the user after using the synchronous support grinding technology? â€œThe user feedback is very positive and the effect is very goodâ€ Guido Hegener said, â€œThis grinding principle is also suitable for machining gearbox shafts up to 600 mm in length, Universal joint shafts, pump shafts or balance shafts. When machining these parts, the new grinding technology shows a huge advantage in terms of efficiency. Compared to conventional grinding processes, the new grinding technology can reduce the cycle time by up to 100%. 70. â€œAt the same time, the quality of processing has also improved.
Principle of synchronous support grinding technology
A typical example of this is the application of new grinding technology in the machining of 4-cylinder camshaft castings. The main shaft of the camshaft is machined in sequence, and the grinding time for each sequence is five seconds. Although the grinding time is short, the precision of the machine's circular runout is guaranteed to be within 10 Î¼m. This accuracy result is much higher than the allowable tolerance limit, and is also significantly better than the processing results of the traditional grinding technology. It is undoubted that this is a qualitative leap.
Camshaft joint machining
Synchronous support grinding technology is not only suitable for round machining, but also for non-circular machining. For example, it is possible to simultaneously machine a cam pot set of a 4-cylinder camshaft, that is to say four grinding wheels are simultaneously ground on one camshaft. The use of this technology not only greatly shortens the processing time, but also improves the contour quality of the cam, which brings double benefits to the user.
Geometrically complex cam profiles can also be synchronized with synchronous support grinding technology
Using EMAG's innovative process, the entire machining process chain of the camshaft â€“ end machining, turning, milling, deep drilling, round grinding and non-round grinding â€“ is done in vertical clamping.
Huge market opportunities
In view of the advantages of the new process, the head of EMAG believes that it has a huge market opportunity should be expected. In fact, the advantages of synchronous support grinding technology are also reflected in other aspects: For example, shorter processing time also means lower energy consumption. â€œCompared with traditional processing technology, the 'single piece of energy consumption' is significantly reduced, and the result is to save operating costs for users,â€ confirms Mr. Guido Hegener. In addition, vertical machine tools occupy a small footprint compared to horizontal machine tools . "The process is economical and efficient, the operation is simple and convenient, and the quality is beyond the color. - Because the synchronous support grinding technology has the advantages that these traditional technologies cannot have, it will become the darling of the market." Guido Hegener is full of confidence and ambition.
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