EMAG Introduces UG 400 Universal Grinding Machine to Streamline Multi-Process Precision Grinding!

EMAG has introduced the UG 400 universal grinding machine, a versatile manufacturing solution designed to simplify precision grinding by combining multiple grinding operations within a single machine platform. Unveiled at IMTS 2026, the new machine integrates internal, external, and out-of-round grinding into one setup, enabling manufacturers to complete complex machining operations without transferring components between multiple machines. By reducing part changeovers and minimising repeated clamping operations, the UG 400 helps improve machining accuracy, shorten production cycles, and enhance overall manufacturing efficiency.

As manufacturers continue to seek higher productivity and tighter dimensional tolerances, the ability to consolidate multiple machining processes into a single platform has become increasingly valuable. Conventional grinding operations often require separate machines or multiple setups for internal, external, and profile grinding, resulting in longer production times, increased handling, and a greater possibility of positioning errors. EMAG’s UG 400 addresses these challenges by allowing all major grinding operations to be completed in one machine, reducing workflow complexity while maintaining exceptional precision throughout the machining process.

One of the primary advantages of the UG 400 is its ability to eliminate unnecessary workpiece changeovers. Every time a component is removed from one machine and transferred to another, there is a risk of introducing clamping inaccuracies, dimensional variation, and alignment errors. By performing multiple grinding operations in a single setup, the machine significantly reduces these risks, ensuring greater dimensional consistency and improved repeatability. Fewer setups also lead to shorter throughput times, reduced labour requirements, and increased machine utilisation, helping manufacturers improve productivity while lowering production costs.

At the heart of the machine is a high-performance direct-drive motor spindle capable of delivering up to 7.5 kW of peak power and operating at spindle speeds of up to 4,500 rpm. This powerful spindle enables the UG 400 to handle a broad range of grinding applications while maintaining stable cutting performance under demanding machining conditions. The machine is compatible with both conventional corundum grinding wheels and high-performance cubic boron nitride (CBN) wheels, allowing manufacturers to process different materials and applications without extensive machine modifications or retooling.

The flexibility to use multiple grinding wheel technologies makes the UG 400 suitable for both conventional precision grinding and high-performance production environments. Manufacturers can optimise grinding operations based on material characteristics, required surface finish, and production volumes while maintaining consistent machining performance across different workpieces.

Another important feature of the UG 400 is its continuously swivelling B-axis, which offers positioning accuracy of ±2 angular seconds. This extremely precise axis movement enables the machine to perform complex contour grinding, angle grinding, and sophisticated profile machining with exceptional accuracy. The high positioning precision also supports the production of intricate component geometries that require strict dimensional control, making the machine well suited for demanding precision engineering applications.

According to EMAG, the machine has demonstrated excellent machining accuracy during testing, achieving roundness values of approximately 0.5 micrometres on test workpieces. Such levels of precision are essential for industries where component performance depends on extremely tight tolerances and superior surface quality. High roundness accuracy also contributes to improved reliability, longer component life, and better overall product performance in critical industrial applications.

The UG 400 offers a grinding length of up to 400 mm and a centre height of either 175 mm or 225 mm, providing the flexibility to machine a wide variety of precision components. Its working envelope makes it particularly suitable for manufacturing precision tools, hydraulic components, gear parts, shafts, and other high-accuracy mechanical components commonly used across advanced manufacturing industries.

The machine has been developed for applications in tool manufacturing, precision engineering, hydraulic systems, gear production, and small-to-medium batch manufacturing. These industries increasingly require flexible production equipment capable of handling multiple component types while maintaining consistent quality and high productivity. By combining several grinding operations within one machine, manufacturers can improve production efficiency while reducing investment in multiple specialised grinding systems.

A rigid machine base further enhances the performance of the UG 400 by minimising vibration during machining. Stable machine construction plays a crucial role in maintaining dimensional accuracy and achieving superior surface finishes, particularly during high-precision grinding operations. Reduced vibration also contributes to longer tool life, improved process stability, and consistent product quality across extended production runs.

The introduction of the UG 400 reflects a broader trend within advanced manufacturing towards process integration and flexible machining platforms. As manufacturers seek to improve efficiency, reduce production costs, and respond more quickly to changing customer demands, multi-process machine tools are becoming increasingly important. Machines capable of consolidating multiple operations not only reduce production complexity but also improve overall manufacturing agility by enabling faster setup changes and more efficient use of factory floor space.

With its combination of internal, external, and profile grinding capabilities, high-precision spindle technology, advanced B-axis control, and rigid machine construction, the EMAG UG 400 offers manufacturers a highly capable solution for precision grinding applications. By reducing part handling, minimising setup changes, and delivering exceptional machining accuracy, the machine supports higher productivity while helping manufacturers achieve the quality standards required in today’s increasingly demanding precision manufacturing environment.