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Is it possible to machine train wheels automatically and flexibly using just one machine? Many users used to think the answer was no. They believed that machining train wheels required multiple machine tools, with several interrelated production stages, and frequent re-clamping of the workpiece, which made the process 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 the entire machining process of train wheels in one go, significantly speeding up heavy-duty machining, improving workpiece quality, and enhancing overall production flexibility.
Heavy-duty machining involves operations like turning, drilling, and high-efficiency milling. The key requirement is handling large or heavy workpieces with high metal removal rates, demanding excellent machine performance. These processes need to be planned strategically rather than focusing on minor details. Train wheel machining is no exception, and many manufacturers still rely on complex, multi-stage setups. But this approach comes with significant drawbacks—high machine startup costs and long processing times due to frequent transfers between machines. “With a single machine, the process is much faster without any transfer,†explains Markus Woitsch, Manager of the Application Engineering business at EMAG.
[Image: Markus Woitsch, Manager, Application Engineering, EMAG Group]
Figure 1: Markus Woitsch, Manager, Application Engineering, EMAG Group
Ensuring precision throughout the process is crucial. EMAG has extensive experience in machining complex workpieces with a single machine. For heavy-duty train wheel machining, they have two key advantages:
- The machine tool is equipped with a spindle, an essential part of its design.
- Multiple operations such as turning, drilling, and milling can be performed in one or two clamping cycles. The VLC 1200 features a turning tool sensor, a milling spindle, and a tool changer to support this.
“By clamping the workpiece only twice, we ensure dimensional accuracy and maintain a high-quality surface finish. Since wheel blanks are expensive, this precise process is especially important for heavy-duty train wheel machining,†says Markus Woitsch. Additionally, the lathe includes a built-in quality control system with a measuring probe that performs real-time detection of the workpiece and process, achieving an accuracy of up to 2 micrometers, which greatly reduces machining errors.
[Image: VLC 1200 for machining train wheels]
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 effectiveness? “The vertical structure is extremely important,†confirms Markus Woitsch. “The workpiece spindle is suspended vertically above the workpiece, allowing chips to fall directly into the chip conveyor and exit the machine. This prevents the workpiece from being heated by contact with hot chips and avoids contamination of the work spindle.†For heavy-duty machining processes with limited manual intervention and high automation, this design offers even greater benefits.
[Image: Turning of train wheels with HSK 100-F160 turning tools]
Figure 3: Turning of train wheels with HSK 100-F160 turning tools