Coldforming Technologies

Worldwide, MAG Powertrain Coldforming Machines are synonymous with top productivity, quality and reliability when it comes to the manufacturing of straight and angular serrations, oil grooves, threads, etc. Our unique experience enables us to provide you with the most economical solution to your specific production requirements. MAG Powertrain is the leading manufacturer of coldforming machines and has all the Know How and technology in designing and manufacturing coldforming racks. They are made of wear resistant, hardened and ground cold worked steel.

Connecting Rod Fracturing & Assembly

The traditional method of manufacturing connecting rods calls for machining the crankshaft and pin bore holes in the connecting rod, and then separating the rod and cap to facilitate installation on the crankshaft. This was a difficult operation requiring extremely high-precision machining to mate surfaces of the rod and cap. The fracturing process pioneered by MAG Powertrain eliminates the complex machining required to achieve precision mating of the cap and rod. Instead, the cap is separated from the rod at a precisely predetermined position by fracturing. The separated faces remain unmachined, their rough surface finish ensuring perfect mating during subsequent connecting rod assembly. The degree of mating accuracy far exceeds that achieved using conventional techniques. This technique: Significantly reduces production costs Minimizes connecting rod production floorspace Reduces tooling, energy and repair costs Is being continuously further developed by MAG Powertrain also for other products Increases the strength of the connecting rod & cap joint.

Machining Centers

Agile manufacturing systems are characterized by high equipment availability with parallel production processes and also high workpiece flexibility. Agile manufacturing systems are combined out of following variations STAR 500 and XS 211, the SPECHT series and the XHC series - linear motor driven machines.

MAG Powertrain: Market leader in dry machining

In each production process, there are processing strategies that can be optimized. Especially here, valuable production time can be reduced and the piece costs can be lowered considerably. For this reason, MAG Powertrain is continuously working on new technologies to reduce or optimize processing times and quality. One example is the minimal lubrication technology. MAG Powertrain designed a new technology for minimal lubrication where the amount of the air-oil mixture can be reduced to a minimum. The air and the oil are sent directly through the spindle to exactly where the lubrication is needed. This drastically reduces the costs for lubricants. Consumption of procedure-specific production materials Practical example: 10 HSC centers in 3-shift mode (yearly consumption) Wet machining Dry machining 750,000 litres of water 500 litres of minimum quantity lubrication 30,000 litres of coolant 150,000 m³ compressed air 1,000 litres of chemical additives 60,000 EURO 7,500 EURO

Multiple Technologies

This machine convinces by its vertical design and the work piece located on top, high technological flexibility, a multiple spindle design and an innovative drive concept. All axes are directly driven and, for the first time, linear motors, which have a considerable influence on the machine dynamics, are used for the X-axes for this machine series. The use of the patented triangular X-slide allows completely independent or parallel machining on smallest spaces.

Special Purpose Machines

Basically, MAG Powertrain is capable of building special equipment to meet any required scope of processing. Beyond this, we can call on special equipment series with which many processing requirements can already be met.

The XHC Machining Center Drive Concept

Use of linear motors results in: High levels of machining accuracy High speeds and acceleration reduce idle times Minimize operational wear and tear for better reliability The following limiting conditions apply with respect to numerous machining tasks in high-speed technology: Cutting time is 30 to 50% of machine cycle time Idle time is 50 to 70% of machine cycle time Therefore the cutting times as well as the idle times - consisting of chip-to-chip-time and positioning times - have to be reduced. The MAG Powertrain solution: Shortest possible cutting times due to high spindle performance and rotational acceleration Shortest possible idle times due to highly dynamic rapid speed Rapid speed rates: up to 120 m/min Axis acceleration: up to 1.4 g Broken tool detection while machine is cycling Shortest chip-to-chip-time (2.6 s) The MAG Powertrain philosophy of high-speed machining includes accomplishing shorter machining times with high levels of machine availability. This requires the use of machine components resistant to wear and tear: Use of a gearless B-axis Use of linear motors in lieu of ball screws The use of linear motors means that conventional transfer elements, such as ball screws, transmissions or clutches, are no longer required. Intelligent, digital drive control units offer the following advantages: High acceleration capability with high contour and positioning accuracy as no mechanical transfer elements are needed High contour accuracy with high path speed due to sensitive interpolation and traction-error-free internal drive position regulation with cycle times of <0.5 ms Since the drive contains no mechanical transfer components, machining can be done completely without backlash High degree of speed with control and accuracy High degree of load rigidity Maintenance free operation as a result of the absence of components affected by wear a Sensor built into the motor coils in the drive control unit monitors temperature and prevents overload damage High resistance to crashes Low force ripples improve surface finish

TransferCenter XT

The TransferCenter XT combines the productivity of a transfer machine with the flexibility of a machining center. By mounting all of the tools in the work area, the TransferCenter XT achieves extremely short machining paths for minimum cycle times. A pick-up type clamping unit automatically locates the workpiece and then transfers it to the various machining stations.