MAG Industrial Automation Systems

Headquarters:

13900 Lakeside Circle

Sterling Heights, MI 48313, USA

tel +1 586 566 2400

fax +1 586 532 3102

Headquarters Europe:

Stuttgarter Straße 50

73033 Göppingen, Germany

tel +49 71 61 201-0

fax +49 71 61 201-353 Co

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The machines shown are examples. Actual machines may vary based on selected options

MAG powertrain combines the operations of some of the world‘s best-known

builders of manufacturing systems and facilities. Using medium-sized business

structures, we generate a multitude of synergies and tremendous added value.

That enables us to offer the machining industry one of the broadest ranges of

manufacturing equipment and systems available – from small standard proces-

sing centers to complex agile manufacturing systems.

Since 2005 MAG Powertrain has been a part of MAG Industrial Automation

Systems, a dynamically expanding group that has achieved a leading position

in the global machine-tool manufacturing industry. With its innovative, highly

productive machine solutions MAG IAS is a strong partner for the metal-working

industries in the aerospace, machining, automotive, heavy equipment, and

energy sectors. A growing number of leading international companies are

relying on the impressive innovative power of the MAG IAS Group to assure

their technological leadership and prepare for future challenges.

MAG Powertrain

Ex-Cell-O GmbH

Salacher Straße 93

73054 Eislingen/Fils

Germany

tel +49 71 61 805-0

fax +49 71 61 805-223

MAG Powertrain

Cross Hüller GmbH

Schwieberdinger Str. 80

71636 Ludwigsburg

Germany

tel +49 71 41 402-0

fax +49 71 41 402-205

MAG Powertrain

Cross Hueller, LLC

2555 20th Street

Port Huron, MI 48060

USA

tel +1 586 566 2400

fax +1 586 532 3102

For information regarding local

addresses and partners visit:

w w w. m a g - i a s . c o m

02 | 03

High Technology, High Efficiency. performance, made by MAG

For manufacturing splines key players of the automotive and components manufacturers trust in the tremendous know-how of MAG Powertrain. Our high-tech cold rolling machines enable an optimal and economical manu-facturing of splines for transmission and driveshaft products. These machines keep MAG-customers always on the right track to success.

The XK Series from MAG Powertrain, based on the Ex-Cell-O coldforming

technology, meets the constantly increasing market demands with three

key features:

, Simplification of tool settings

, Further improvement of workpiece quality

, Increase in flexibility

All movements are performed by numerically controlled axes.

This results in special advantages to the customer:

, Dimensional correction via control system off-sets

, Possibility of reverse rolling to achieve a symmetrical

tooth shape

, Variation of workpiece tooth quantity without changing tools

, Spacing error correction

, Vertical feed during rolling

, Rolling speeds are individually programmable

, No hydraulic power pack needed for the electromechanical axes,

therefore the required floor space and noise level is reduced

new Approaches have been taken to Optimize this Technology

, Analysis of the forming process with the aid of FEA simulation

, Process control with targeting influence on the process,

particularly suitable for hollow shafts

, Innovative tool design to increase tool life

, Optimized machine guarding concept

XK 8xx Series:Innovative coldforming withprocess control

04 | 05

Step 2

Step 100

3D detail

forming simulation of the coldforming process

Wedge slides forvertical feed of tools

Machining Machining Wedge slides forvertical feed of tools

Control via electromechanical axes

coldforming – and How it Works

The chipless coldforming of profiles such as splines (straight or helical),

spiral serrations, oil grooves, and threads only takes seconds with the

MAG Powertrain coldforming process and is up to 30 times faster than

chip removal methods.

In addition, coldformed workpieces have a higher load capacity and a better

surface finish and accuracy. Involute gears and profiles can be produced

very quickly and precisely with this process.

The high precision coldforming racks roll and press the required profile

into the workpiece during the coldforming process. The material is displaced

and flows into the free spaces of the racks. The workpiece is pressed twice

during one rotation, i. e. forming takes place in a series of steps.

The height of the ground profile in the forming rack increases progressively

into the forming area. This causes each rack tooth to press slightly deeper

into the material than its predecessor. After reaching the full profile depth,

the form is optimized in geometry and surface finish in the calibration zone.

This is followed by a relief zone with decreasing profile depth.

clone rolling Technology

Two parts are positioned in pre-locator and clamped between centers.

The racks are positioned to clamp part for the rolling process. This can

achieve for example within 22 seconds two workparts with two splines

and numbering each.

Advantages are a very fast cycle time combined with high productivity

and little additional costs.

3 phases of the coldforming process concept

the workpiece is located and clamped between two live centers

two synchronous coldforming racks simultaneously engage the workpiece from opposite sides, causing it to rotate. during rotation, the required profile is formed progressively as the racks complete their strokes

After a few seconds, the rolling process is complete. the workpiece is removed, and the racks return to their initial position

Advantages of MAG powertrain coldforming Technology

06 | 07

A definite advantage of the these coldforming technology is the

omission of the usual profile undercut for milling tools – the racks

can extend to nearly the same level as the shoulder.

Advantages of coldforming Technology

, Forming with minimum lubrication = no cleaning is needed after forming

, High contact ratio during forming

, Achieves a high efficiency with minimal thermal effects

, Axial tapering enables easy fitting of spline shafts at tooth end

, Simultaneous machining of several profiles

, Keeps grooves free from debris

, Labeling the workpieces

rollable Materials

Acceptable materials for rolling parts on MAG Powertrain machines include

all alloyed and non-alloyed carbon steels with a coefficient of elongation

over 7%. A homogeneous structure is important. Usually, materials with

tensile strengths between 600 and 800 N/mm2 and in special cases

also materials with a tensile strength of 1,200 N/mm2 can be rolled.

Typical materials are: Cf 53, 16 Mn Cr 5, C 45, 42 Cr Mo 4, 14 Cr

4 as well as other alloys. Forged or coldformed parts are annealed

before rolling.

High contact ratio rolling principle for keeping grooves free

rolling principle for axial tapering at tooth end

Other Advantages of the process

In addition to the already mentioned possibilities like coldforming of

serrations or oil grooves close to the shoulder, this process also allows

the rolling of a serration to any given radial positioned workpiece design

feature within a tolerance of ±45 minutes. For this situation, a so-called

“ratchet” can be made to prevent radial orientation assembly errors.

Machine Automation

Due to short cycle times the machine was designed with modularity in mind

for multiple mountings for various types of automation. Shortest cycle times

are achieved as the change between rolled and unrolled parts already takes

place during the return stroke of the machine slides. MAG Powertrain offers

standard automation that provides a reliable interface with existing

or new transport systems. For example, it is also possible within the scope

of automation to measure the premachined diameter of profiles that are

to be rolled in order to avoid tool breakage and to ensure constant profile

quality. Measuring equipment for rolled gear cutting is also available.

premachining of a Workpiece

The diameter for premachining of workpieces is theoretically calculated by

means of a computer program developed by MAG Powertrain. Workpieces

manufactured according to this process are measured after test rolling, and

possible corrections as well as the final dimension for volume production

are determined. This diameter must be manufactured with a tolerance of

0.02 to 0.05 mm, depending on the specified tooth gear quality.

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. Worn coldforming racks can be reground at the cold-

forming rack center. Here, new ideas, machines, systems and work cycles

have been implemented for optimized manufacturing of coldforming racks

– the results are short lead times as well as the highest possible accuracy

and quality. Coldforming racks are CAD designed with a computer program

developed by us. The entire production process is computer controlled.

A well-trained team of specialists is responsible for the entire manufacturing

process, all the way from concept to production. Inventory of semi-finished

racks considerably shorten delivery times for new coldforming racks.

The quality of the coldforming tools and the machined workpiece profiles are

measured and controlled by MAG Powertrain on a special profile measuring

machine.

Original MAG powertrain racks for coldforming Machines

08 | 09

Coldforming racks configurations

Spline Standards

In general, all involute splines can be rolled. The common standards are:

DIN 5480, ISO 4156, ANSI 92.1-1970, ANSI B 92.2M-1980 and GOST

6033-51. The profiles shown can be rolled with a pressure angle of 25 to

45 degrees in accordance with the restrictions for maximum profile sizes

shown in the chart on page 10. Additionally, special profiles with other

standards can also be rolled.

MAG Powertrain coldforming racks are made of heavy duty, hardened and

ground cold worked steel. Depending on part material and profile, 25,000

to over 300,000 working cycles can be performed with one set of racks.

Racks can be reground several times. Their length is dependent on the type

and size of the respective workpiece. Thread racks, oil groove racks and

knurl racks generally require a tool length of 330 mm. Other standard rack

sizes and their possible set-up combinations are shown in the chart.

Grinding outer contour

Grinding of threads Grinding forming profile

Grinding outer contour

Grinding of rack base

Grinding outer contour

demagnetize

Grinding front face

finish control

testmachine

Preparation of test parts for try out of racks

finish assembly

Manufacturing center for precision center coldforming racks at MAG Powertrain

Special racks

Spherical radius at Tooth End

,Less stress peaks at end of serration, especially suitable

for high strained workparts

Helical Double Serration with Groove

, Pinion cannot move back after turning by one tooth (fixed rest)

, Rolling of two different splines simultaneously

, Including clearance of groove

clearance of Grooves

, Non material flow into the grooves for lock rings.

This will avoid additional machining

XK 837

XK 851

XK 875

Technical Data XK 8xx Series

10 | 11

XK 8xx XK 837 XK 851 XK 875

length mm 4,500 4,850 5,540

Height mm 2,490 2,490 2,490

Depth mm 1,800 1,800 1,800

Depth with Under-/Overarm mm 4,200 4,200 4,200

Slide Stroke mm 1,200 1,500 2,100

Slide length mm 1,370 1,670 2,270

clamping Width max. mm 370 370 370

Tool length max. mm 915 1,220 1,500

Feed Force max. kN 40 40 40

Feed rate max. m/min 30 30 30

radial Force max. kN 400 400 400

radial Vertical Feed per Side max. mm 6 6 6

Vertical Feed rate max. mm/s 1.5 1.5 1.5

profile-Diam max. (standard)* mm 60 60 60

profile length (standard)* mm 180 180 180

Standard Module range mm 0.3–3 0.3–3 0.3–3

Machine Opening (standard)* Zoll 6 6 6

Weight without Automation t 18 19 20

XK 2xx Hydraulic Version

without Automatic Adjustment XK 225 XK 237 XK 251 XK 275

Overall Width mm 5,200 5,200 5,200 5,200

Width of Machine mm 2,740 3,075 4,245 4,800

Depth without Outboard Support mm 2,700 2,700 2,700 2,700

Depth with Outboard Support (585 mm Stroke) mm 4,600 4,600 4,600 4,600

Height mm 2,360 2,360 360 2,360

Weight without Automation kg 9,800 12,000 13,800 14,500

Motor Size (Standard)* kW 15 15 30 30

Hydraulic Tank capacity l 1,000 1,000 1,000 1,000

Slide Stroke max. mm 810 1,160 1,560 2,050

rack length max. mm 610 915 1,220 1,500

profile Diameter max. (Standard)* mm 5O 5O 60 60

profile length max. (Standard)* mm 125 125 125 125

Standard Module range m 0.3–1.25 0.3–1.25 0.3–1.25 0.3–2.0

* Deviations from standard on request

* Deviations from standard on request

MAG Maintenance Technologies is your single source for maintenance

and productivity solutions designed to optimize plant operations. Through

comprehensive support and factory-direct expertise, manufacturers achieve

maximum equipment availability and utilization reducing their cost per

piece. By providing an award-winning service and support program, our

customers maintain the lowest possible total cost of ownership of capital

equipment throughout the machine’s life cycle.

consider these benefits of MAG Maintenance Technologies:

, Better understand and manage your factory life cycle costs

, Increase your throughput efficiency and lower total cost of ownership

, Reduce your maintenance costs

, Prolong your machine’s life

, Increase your opportunities to win contracts

Supporting the machine tool brands you know and trust – more

than 50 brands – MAG Maintenance Technologies serves your

needs before, during and after installation of your equipment by

providing the industry’s broadest range of services, including:

, Installation, relocation, rigging and training services

, Factory optimization, tooling and application solutions

, Service parts, field service and call center support

, Preventive maintenance, machine certification, repair

and exchange services

, Rebuild, retrofit, remanufacture and retool services

With global parts and service operations positioned in Europe, China, South

America and North America, MAG Maintenance Technologies is a unique

worldwide service and support organization that helps extend equipment life

and maximizes return on your capital investment.

Our four global hubs are strategically located to ensure

that you receive prompt and accurate service and support.

locations include:

, North America (United States)

, Europe (Germany)

, Asia (China)

, South America (Brazil)

MAG Maintenance Technologies is committed to providing the highest level

of service to its customers, delivering solutions that improve productivity

and generate sustained growth for industrial manufacturers. For more

information, visit www.mag-ias.com.

Factory-direct Support provided by MAG Maintenance Technologies

Technical data subject to change without notice