Model Overview and Range of Applications

The series is divided into four variants:

• UG 400 with a grinding length of 400 mm

• UG 630 with a grinding length of 630 mm

• UG 1000 with a grinding length of 1,000 mm

• UG 1500 with a grinding length of 1,500 mm

Linear guides in the X and Z axes, servo drives with ball screws, and direct-drive motorized grinding spindles form the technical foundation. The standard center height is 175 mm and the maximum workpiece weight is 120 kg (UG 1000 model). Larger center heights and workpiece weights are possible with optional equipment.

Grinding Headstock – Precision Through Direct Drive

The grinding headstock is equipped with direct-drive motor spindles. The spindle power is up to 11 kW. By eliminating the belt drive, sources of vibration are eliminated and torque is transmitted without loss. This results in uniform power transmission and reduces vibrations during the grinding process.

The automatically swiveling B-axis enables stepless positioning between -15° and +225° with an accuracy of 0.0005°. This precision is required for face and contour grinding, where the exact angular position of the grinding wheel determines the machining result. The achievable peripheral speed of the grinding wheel is 50 m per second. Precision grinding spindles are used for internal machining. These spindles are characterized by high rotational speeds and robust bearings with oil-air lubrication, which is required for the internal grinding of small bores.

Workpiece Spindle Head – Rigidity and Concentricity

The workpiece spindle head is equipped with precision tapered roller bearings that ensure high rigidity. This achieves a concentricity accuracy of 0.5 µm on the test workpiece.

A swivel range of 0° to +30° enables various grinding strategies for taper grinding. Workpiece setup and positioning are facilitated by a pneumatic lifting device. Optionally, AE sensors can be integrated to detect contact between the grinding wheel and the workpiece, thereby reducing idle times.

For out-of-round and thread grinding, a workpiece spindle with a C-axis is available as an option. In this case, the workpiece spindle is designed as a motor spindle with rotary positioning. This enables synchronized movements between the feed of the grinding spindle and the rotation of the workpiece.

Tailstock – Precise Centering During Grinding Between Centers

The tailstock is equipped as standard with a quill having a diameter of 63 mm for MK4 centers. It runs without play in the guide, which enables precise centering of the workpiece. A fine adjustment of ±40 µm allows for the correction of taper deviations and ensures concentricity accuracies of well under one micrometer.

Dressing Systems – Ensuring Consistent Grinding Conditions

Various dressing systems are available to meet different requirements. Dressing is an essential part of the grinding process, as the geometry and sharpness of the grinding wheel significantly determine surface quality and dimensional accuracy.

The following systems are available:

- Table dresser with flexible positioning: The table dresser can be placed at any position on the upper table. This flexibility allows adaptation to different workpiece geometries and grinding wheel diameters. The user can optimize the dressing position for each specific workpiece, which reduces setup times for frequently changing production tasks.

- Dressing spindle on the workpiece headstock: The dressing spindle is mounted at the rear of the workpiece headstock and enables automated dressing without manual intervention. This solution is suitable for series production, where constant dressing cycles increase process reliability. Integration into the machine structure reduces space requirements and shortens non-productive times.

- Holders for dressing tiles on the tailstock and workpiece headstock: For simple dressing tasks, holders for dressing tiles can be mounted on the tailstock or workpiece headstock. This cost-effective solution is suitable for manual dressing operations or as a supplement to automated systems.

The modular design allows the dressing system to be adapted to the specific application. The selection of the appropriate dressing system depends on the type of grinding wheel, the number of pieces, the workpiece geometry, and the required surface qualities.

Of course, the machines in the UG series can be expanded according to customer requirements, for example with an NC synchronous tailstock, in-process measurement technology, an automatic tailstock with an NC axis, a hydraulic steady rest, and many other options.

Control and Operation

UG machines come standard with the FANUC 0i-TF CNC control system. This control system features a dialog-based HMI that simplifies programming and operation. The user interface is logically structured, and frequently used functions are directly accessible.

For more complex contours, particularly in non-circular and thread grinding, the FANUC 31iB Plus is available. This control system features higher computing power and supports advanced functions for synchronized motion control. Interpolation between the axes is performed with high precision, which is necessary for machining non-circular geometries.

The use of FANUC controls offers advantages for international operations. The controls are widely used worldwide, service availability is high, and spare parts are available on short notice. This minimizes downtime and facilitates the training of operators who are familiar with FANUC controls.Global Customer Support

EMAG maintains a global service network covering all continents. Service locations are situated in Germany, the United Kingdom, France, Spain, Italy, the USA, Mexico, Brazil, India, China, and South Korea. This decentralized structure enables short response times and a rapid on-site presence for service requests.

Service technicians at all locations draw on a shared knowledge pool. Experiences from service cases are systematically analyzed and made available worldwide. As a result, customers benefit from the EMAG Group’s collective expertise regardless of their location.

As an OEM supplier, EMAG guarantees to assist the customer as quickly as possible—whether during commissioning, with technical questions, or in the event of a malfunction. Upon request, EMAG delivers a turnkey package that includes not only the machine but also tooling, clamping technology, cooling lubricant, and the finished workpiece program. The customer thus receives a production-ready solution from a single source.

The service program also offers preventive maintenance, training at the EMAG Academy, retrofits, and original spare parts available at any time. The goal of all services is to maximize machine availability and ensure a long service life for the investment.

Source | EMAG