From new passenger cars with electric motors to the ongoing e-bike boom – the electric revolution in private transportation is picking up speed, and challenging production planners in the industry. How can the production of rotor carriers, rotor shafts, and similar parts be made even faster, more efficient, and precise in the future? At the recently concluded Technology Day, the experts at EMAG ECM gave detailed answers to these questions. Technical lectures by scientists, ECM presentations, and live machine demonstrations showed clearly how electro-chemical machining (ECM) can be used to achieve exceptionally effective production processes for e-mobility and other industries.
Electric motor production creates new challenges for production planners in many companies: drive shafts and gearing components often have complex geometries and must be built with thin walls to save weight – and may even have bore holes with complex intersections. In addition, these components need to be precisely made with lean process chains. All of the above factors have contributed to the growing importance of electro-chemical machining in e-mobility and other industries.
At its second ECM Technology Day, the experts demonstrated why EMAG ECM (electro-chemical machining) is so successful here. “We really got into the details at this event and were able to show how, in the future, it will be possible to produce even complex parts with a lean and cost-effective ECM process chain. The processes include ECM broaching, ECM drilling, and ECM deburring,” explained Richard Keller, member of the management board of EMAG ECM, Gaildorf.
The ECM experts also explained the overall advantages of their method, which function without contact between the tool and the workpiece. There is no heat warp and almost no tool wear, and the surface quality is very high. The ECM process creates no burrs, eliminating the need for additional deburring processes in many applications. This is independent of the material hardness. EMAG presented a new, (P)ECM machine, at a significantly discounted price, in an early state of development, which will be ready for use in the near future.
The agenda was rounded off by a variety of interesting ECM application examples, some demonstrated on live machines during a guided tour of the factory. In addition, visitors saw ECM machine types that are used as stand-alone solutions or as parts of modular systems - including the compact entry-level model CI 400, the modularly scalable and therefore extremely cost-effective CS stand-alone machine, the PO 900 BF, and the PO 100 SF for machining complex components for jet engines.
Richard Keller added, “We are delighted about the amount of positive feedback from our visitors, who were excited about the event’s varied agenda and the high level of the technology and scientific presentations. The mix of scientific lectures, engineering know-how, and the opportunity for exchange with experts lent the event excellent practical value.”