processes Efficient
processes Efficient coating of brake discs – and compliance with EURO 7 regulations The EURO 7 standard will change the automotive industry immensely: for the first time not only emissions from combustion engines will be regulated but also the abrasion of brakes, among other things. The initial conclusion is that the particulate matter, produced by many models must be significantly reduced. As a result OEMs and suppliers are looking for a new solution for the braking system, with coated brake discs currently proving to be the ideal solution for the task. But how can the various coating systems be applied reliably and efficiently in high-volume production? EMAG gives an answer: a complete solution ready for series production for the coating of brake discs by laser deposition welding, which has already proven itself in production. But what distinguishes it in detail? The problem is as simple as it is quickly explained. From the EU’s point of view conventional braking systems produce too much particulate matter, with the new limit values of the EURO 7 standard leading to a very large technological “gap” between the particulate matter emissions of current and future models. The upper limit for all new vehicles is now only 7 mg of particulate matter per km. Today, however, a car emits up to 40 mg, depending on the model. For manufacturers of larger models (with higher particulate emissions), this change is associated with a development task, especially as the brakes are a safety-critical component whose design is very complex in detail. The focus here is primarily on the two “friction partners” brake disc and brake pad, as their interaction generates the particulate matter. A technical challenge So what options are there for reducing particulate matter? This question has been on the minds of developers for some time, and extraction systems near the brakes, for example, have proven to be a problematic approach. On one hand, only part of the emissions is extracted in this way, on the other, manufacturers would have to plan for additional installation space and accept higher unsprung masses. The use of so-called NAO brake pads (Non-Asbestos Organic) is no satisfactory solution, as particulate emissions only decrease with brand-new brake discs. After a short time in use they rise again to the current level. In this context hard coating of brake discs is emerging as the ideal solution. The conventional brake disc is simply given a new layer that offers protection against corrosion, wear and fine dust. Hard coatings of brake discs are nothing new in principle, but they have so far only been used in a niche markets due to high production costs. One reason being that thermal spraying and electroplating do not create a metallurgical bond to the base material. As a result complex pre-processing is required to bond the coating. In addition the layers are (too) thick and the heat input is high. In this context a new Laser deposition welding is used to apply a hard coating that protects brake discs from corrosion and wear development from EMAG in the field of laser cladding of brake discs represents a quantum leap for this task. The new production solution is economical, suitable for large scale production, reliable and variable, as a variety of material combinations can be used for coating. ELC 450 LMD – modular machine solution for laser metal deposition The ELC 450 LMD is an innovative machine solution from EMAG that is characterized by its modularity and flexibility. The basic idea behind it is the use of process modules that can be combined and expanded according to customer requirements. The machine is available in various configurations, depending on the number of process modules. The basic version, the ELC 450 LMD, has one process module. The ELC 450 DUO LMD has two process modules, and the ELC 450 TRIO LMD, as the name suggests, uses three process modules. These modular machine concepts make it possible to optimally meet customer requirements in terms of shift structure and productivity. This determines the choice of machine configuration. The ELC 450 LMD can realize both 1-shift and 2-shift systems. The combination of laser power and application rate determines the most suitable machine concept for the respective application. The longer service life of coated brake discs also has a positive effect and helps reducing the environmental impact. In contrast to conventional brake discs, coated brake discs have a significantly longer service life, meaning lesser replace - ments. This reduces the need for new brake discs and helps to reduce the environmental impact of their manufacture, transportation and disposal. In addition the new generation of brake discs reduces vehicle maintenance, saving time and money. In this way the coating of brake discs offer a sustainable solution. further information: www.emag.com 36 no. 2, May 2025
Exploring and shaping the world of machine tools with the Tokn machining center In September 2024 HELLER celebrated the premiere of the Tokn at AMB trade fair. The name ‘Tokn’ stands for the symbolic key that opens the door to the world of machine tools in an easy-to-understand way. The Tokn is both the tool that is used and the machine to be designed and assembled. Development and production processes and conditions become real-life experiences. The small-size version of a large HELLER CNC machine tool offers the same functionalities as its larger siblings, with additional benefits for the training of skilled workers. In the 1980’s HELLER developed a completely new educational and practical tool to improve the presentation and trans fer of NC technology knowledge: the CNC ProfiTrainer, the predecessor of today’s Tokn. To date, numerous young people have received professional training on the educational tools at the company’s training department. In the academy training center a wide range of users and customers have experienced the training system first hand. With the aim of further improving identification, acceptance and operability, the Nürtingen-based company decided to give the spacesaving, mobile tool a modern look as part of a design facelift. In recognition of these efforts, the design received the German Design Award 2025 in the category ‘Excellent Product Design – Industry’ for outstanding design quality. “We created the Tokn to give young people the opportunity to be able to experience and actively shape the world of machine tools”, says Achim Hammley, responsible for the project at HELLER training. With the Tokn trainees assemble a complete miniature machine tool with a small, manageable size. At the same time the Tokn is used for CNC training. “In the CNC course each of our apprentices learns how to use the machine to manufacture workpieces”, continues Hammley. The tool is also used for customer training, allowing them to train their specialists in the optimal use of HELLER machines. This not only opens up new ways of delivering technical education, but also encourages collaboration between educational institutions, industry and technology providers. These partnerships are critical to meeting the demands of modern production environments and ensuring that training programs remain current and relevant. Big impact from a small machine Unlike the original HELLER machine tool and other training systems, the Tokn is mobile and can be taken to the operator’s workplace. The Tokn is designed, manufactured and commissioned by apprentices at Gebr. Heller Maschinenfabrik GmbH in Nürtingen, Germany. The linear axes move the tool, the rotary axes move the workpieces. As with the machining centers from the current model range, the control system and control cabinet are fitted with real control components. The Tokn is equipped with the latest CNC control from Siemens, the SINUMERIK ONE, combined with an intuitive user interface enabling trainees to work with high-performance machines right from the beginning. With this generation of the control system unprecedented possibilities like the digital twin find their way into everyday working life. The programs can be tested and run on the training tool in the same way as on the original machines. Even actual machining of components is possible. All operating functions of the HELLER machines are integrated. Machine functions that cannot be performed are simulated via runtimes in the control.. Other features of the 5-axis machine include integrated work area lighting and an external, height-adjustable control panel. The use of this CNC training system allows skilled workers to be trained in a targeted, practical and hands-on manner, training them in the safe operation of machining centers and allowing to carry out real machining operations on a fully configured machine. The concept helps to overcome fears and reservations, as people are often less intimidated by small things than by the large originals. Tokn on tour In order to communicate the benefits and the concept, HELLER has launched the ‘Tokn on tour’ campaign, where the Tokn will be presented and demonstrated at numerous trade fairs and training events. The small teaching and learning machine is very popular and frequently on the road. In autumn 2024 it was presented at the Siane exhibition in Toulouse and then at Precisibeurs in the Netherlands. This year the Tokn will take part in more than ten events in various countries, including China, the USA, Poland, France, England and Germany. further information: www.heller.biz no. 2, May 2025 37
