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

Is it possible to automatically and flexibly machine train wheels using just one machine? Many users would say no. They believe that machining train wheels typically requires multiple machine tools, with several interrelated production stages. This often involves repeated clamping of the workpiece, which can be time-consuming and inefficient. However, the EMAG Group has introduced the VLC 1200 multi-functional machining center, a solution designed with deep industry insight. This machine makes it possible to complete all necessary machining operations for train wheels in a single setup. Heavy-duty machining involves tasks like turning, drilling, and high-efficiency milling, but the key is handling large or heavy workpieces with high metal removal rates. The process must be planned strategically, not just focused on small details. Train wheel machining is no exception, and many manufacturers still rely on complex, multi-stage processes. But these methods come with significant drawbacks. For example, changing workpieces often means restarting the entire production chain, which increases downtime and costs. In contrast, using a single machine allows faster processing without any transfer between machines, as noted by Markus Woitsch, manager of the application engineering business at EMAG.  **Figure 1: Markus Woitsch, Manager, Application Engineering, EMAG Group** Ensuring precision in the process is crucial. EMAG has extensive experience in machining complex workpieces with a single machine. When it comes to heavy-duty machining of train wheels, they have two key advantages: - The machine tool features an integrated spindle, a core part of its design. - It can perform multiple operations—such as turning, drilling, and milling—on one machine, requiring only one or two setups. The VLC 1200 is equipped with a turning tool sensor, a milling spindle, and a tool changer. “By clamping the workpiece only twice, we ensure dimensional accuracy and maintain a high-quality surface finish,” explained Markus Woitsch. “Since wheel blanks are expensive, this precise process is especially important for heavy-duty machining.” Additionally, the lathe includes a quality control system with a measuring probe that performs real-time detection, achieving an accuracy of up to 2 micrometers and significantly reducing machining errors.  **Figure 2: VLC 1200 for machining train wheels** The design of the machine plays a critical role in its success. How does the vertical structure of the EMAG VLC 1200 contribute to its performance? “The vertical structure is extremely important,” said Markus Woitsch. “The workpiece spindle is suspended vertically above the workpiece, allowing chips to fall directly into the chip conveyor and exit the machine, preventing heat buildup from hot chips and avoiding contamination of the work spindle.” This design becomes even more advantageous for heavy-duty machining processes that require minimal manual intervention and high levels of automation.  **Figure 3: Turning of train wheels with HSK 100-F160 turning tools**

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