The growing purchasing power of middle-class consumers in Asia has led to an increase in spending on consumer goods. In a rush to meet the escalating demand, manufacturers catering to the APAC region are investing in new production plants and machines, creating a requirement for machine tools in the process. An analysis by Frost & Sullivan reveals that this requirement will push the Asia-Pacific machine tool market to grow at a CAGR of 2.2 percent from 2018 to 2023, reaching $10.5 billion in revenue.
“Business expansion strategies and plant localisation of end-user industries are set to drive the growth of the machine tool industry in the APAC region,” said Divya Saiprasad, Principal Consultant, Industrials at Frost & Sullivan. “The rise in demand for machine tools can be attributed to the increase in the production of auto components and growth of the automotive industry.”
Japan, South Korea, and Taiwan are expected to remain the top three markets for machine tools in the region in 2023, contributing 69.5 percent. Additionally, emerging economies such as Vietnam, Indonesia, and Thailand are anticipated to showcase strong growth over the next three years, driven by foreign direct investment (FDI) inflow in the manufacturing sector.
“On the end-user vertical front, engineering and automotive sectors are projected to remain dominant,”noted Saiprasad. “The aviation sector is also expected to further supplement the market for machine tools, given the demand from the burgeoning upper-middle-class population.”
Machine tool vendors can tap into further growth by:
Integrating new features and technologies into additive manufacturing to increase the overall efficiency of multi-tasking machine tools.
Including new technologies such as IoT and Big Data for preventive and predictive maintenance of machines to help machine tool companies enhance their customers’ rate of operations in manufacturing, thereby increasing their brand recognition in the market.
Developing and selling smart machines equipped with AI, robots, and software technologies to expand sales and improve the productivity of customers in ASEAN countries.
Increasing production efficiency, shortening delivery times, and maintaining price competitiveness to increase sales and improve market profitability.
Expanding sales, distribution, and aftermarket service channels in emerging Asian countries to retain customers.
Step-by-step networking for in-house manufacturing, involving suppliers and customers and efficiently using data together – the digital services provided by c-Com, a member of MAPAL Group, make it all possible. However, the start-up isn’t just developing its own applications. It’s also generating added value for customers by working closely with cooperation partners.
Cooperation with MARPOSS: reduced setup times and maximum tool service life
The optimal and longest-possible use of tools represents a vital cost factor for machining companies. But compromises are often necessary – particularly in series production and as part of automated processes. Tools with a defined tool life are replaced as soon as the specified tool life has come to an end. In many cases, though, the tool has not truly reached the end of its tool life and replacement is not yet necessary. However, companies play it safe to avoid quality issues and the risk of producing items that later need to be rejected.
This is one of the elements addressed by the ARTIS GENIOR MODULAR module by MARPOSS. The fully automatic tool- and process-monitoring system has been an established feature of the market for many years. It works by recording various measurements and assessing them on the basis of several criteria.
MARPOSS recently launched a collaboration with c-Com GmbH and its c-Com open cloud platform to provide module users with additional value: the ARTIS GENIOR MODULAR module and c-Com are set to exchange data. Once the defined tool limits have been reached, the staff member responsible receives a notification on their mobile terminal – which is made possible by the cooperation with c-Com. As a result, operators can react more quickly and boost the efficiency of their manufacturing processes.
Cooperation with Oerlikon Balzers: transparency and sustainability thanks to digital processing for coating
Many tools are re-sharpened and re-coated to make production as cost-efficient as possible and to use raw materials sustainably. This procedure is very complex for everyone involved – from the machine operators to the staff members carrying out the re-sharpening and coating. If a staff member responsible for re-sharpening sends a tool for coating, this staff member is often not aware of corresponding order status. This results in frequent queries. In some cases, the number of re-sharpening processes is simply marked on the tool shank. Overall, the total benefit is reduced by the very high investment of time and effort required.
In cooperation with Oerlikon Balzers, c-Com has developed an application that enables significantly more effective and transparent order processing. The prototype was showcased at EMO Hannover. The only prerequisite to benefitting from the advantages of digital processing for coating is identifying all tools with a unique ID.
The c-Com application exchanges data with the myBalzers customer portal run by Oerlikon Balzers. This way, the entire order process is digitalised, and all receipts are available online. It is easy to share documents such as delivery slips, invoices or order confirmations, and the status of each coating order can be viewed in real time. There is no longer a need to ask for order updates – a quick glance at the application provides the user with all the information they need. On top of this, machine operators have access to all the important information about their tool at all times. Thanks to the collaborative approach by c-Com, they can access all data via the cloud.
The c-Com wear detection app: a technical advisor in your pocket
c-Com has developed a wear detection application to provide answers to these questions. The prototype for the application was presented at EMO Hannover. The application is very simple to use: first, the worn blade is documented using a smartphone and a conventional auxiliary lens for zooming in. The app then identifies the type of wear and suggests corresponding recommended actions. This allows users to prevent this type of wear in future.
The application is based on machine learning, a sub-category of artificial intelligence. This means that the application uses datasets to learn. Together with tool specialists at MAPAL, c-Com has compiled and categorized hundreds of images. Effectively, the algorithm was trained by being shown what different types of wear look like, allowing it to assess whether or not a blade is in good order.
Reducing CO2 greenhouse gas emissions has a considerable impact on the development of machining tools, as new fields of application are emerging, and existing ones need to be adapted. This is because alternative drives, new, lighter materials, and concepts that save energy and resources are now more in demand than ever before. Article by Walter AG.
The Walter Xtra·tec XT shoulder milling cutter and face milling cutter are suitable for virtually all requirements in shoulder and face milling, in all common material groups.
Reducing CO2 greenhouse gas emissions has become an objective throughout the world. In many places, there are now discussions about imposing taxes on CO2 emissions. The German government has set itself the objective of reducing carbon dioxide emissions in Germany by 55 percent by 2030.
This also has a considerable impact on the development of machining tools, as new fields of application are emerging, and existing ones need to be adapted. This is because alternative drives, new, lighter materials, and concepts that save energy and resources are now more in demand than ever before. Developers see great potential in design modifications to tools, new coatings, new machining strategies, and digital solutions, which respond to the existing framework conditions in real time.
Increase Tool Life
The current trend is for new, lightweight aluminium-lithium alloys. These materials quickly overwhelm conventional tools, resulting in an increasing demand for high performance tools specifically designed for this range of applications.
For instance, aircraft components made of aluminium alloys often have machining volumes of up to 90 percent. Depending on the required component geometry, numerous bevels and cavities need to be milled out of the metal, with the goal of ensuring stability and reducing weight. To manufacture the components economically and to a high quality, they need to be machined using high speed cutting (HSC) processes involving cutting speeds of up to 3,000m/min. Cutting values that are too low lead to build-up on the cutting edge, and therefore result in rapid wear and frequent tool changes. This results in high costs due to long machine running times. Machine operators specialising in aluminium therefore have good reason to demand above-average cutting data and tool life from their tools, as well as particularly high process reliability.
With the design of the M2131 ramping milling cutter, the tool developers at Walter AG have shown how such complex requirements can be dealt with. The 90 deg milling cutter is equipped with a new class of indexable inserts, with the grade designation WNN15. This refers to a new PVD coating, which is manufactured using the HIPIMS method. The term HIPIMS stands for “High Power Impulse Magnetron Sputtering”, a technology based on magnetron cathode sputtering. The special feature of the physical coating process is that it produces an extremely dense and smooth PVD coating, which greatly reduces friction and the tendency to cause built-up edges. At the same, this method increases cutting edge stability and resistance to flank face wear, enabling a maximum metal removal rate as a result. Field tests have confirmed the advantages of HIPIMS indexable inserts compared to standard types. Increases in tool life of up to 200 percent were achieved.
“We are seeing an increasing demand for high-performance tools for machining aluminium, particularly in the aerospace industry but also increasingly in the automotive industry,” explains Wolfgang Vötsch, Senior Product Manager for Milling at Walter AG.
Suitable workpieces, milling tools, machines and CAD/CAM systems are required for the dynamic milling strategy. Image: Walter AG
Milling Strategy with a Focus on Efficiency
Many sectors, particularly the supply industry, are under pressure to provide increased process reliability and faster machining—at ever lower costs and with consistent quality. The demands for surface quality and dimensional stability are often increasing at the same rate as requirements for process reliability and cost efficiency. Moreover, there is a growing need for lightweight or heat-resistant materials. However, these materials from the ISO M and ISO S material groups are often difficult to machine precisely because of these properties.
Dynamic milling provides a solution in this area, offering both productivity and process reliability. This is why a growing number of metalworking companies are relying on this method.
High Performance Cutting vs. High Dynamic Cutting
The main differences between conventional high performance cutting (HPC) and high dynamic cutting (HDC) are in the movement of the milling cutter and the forces generated. During HPC, the milling tool moves with relatively low depths of cut. During HDC, the CAD/CAM control system adapts the machining paths so that the tool moves according to the shape of the workpiece. This prevents non-cutting time, or at least reduces it. Moreover, the depth of cut is significantly greater during HDC than during conventional HPC, meaning that travel distances are also reduced because the complete tool length can be used.
The engagement angle is usually very large during HPC. The forces that occur in the process are accordingly high. This in turn quickly causes signs of wear to appear on the tool and the machine spindle. Dynamic milling, on the other hand, is characterised by a high level of process stability and a long tool life. The engagement angle chosen for HDC is normally small, meaning that the forces which impact the tool and machine are much lower than for HPC. Higher cutting parameters, less non-cutting time and increased process stability result in a much higher metal removal rate for HDC milling compared to HPC.
Cutting Data Optimisation Using Live Data
Automation, digitalisation and networked processes have been everyday aspects in many areas of metalworking for a long time. In particular, the hardware and software used to collect and analyse live data have produced huge leaps in performance.
The Comara iCut software tool demonstrates how this provides opportunities to optimise processes. The adaptive feed control analyses incoming machine data in real time and adjusts the machining accordingly. This answers one of many users’ key questions. Namely, how can you get the most out of a machine without making major changes to the process or carrying out complex reprogramming work?
The iCut software enables the machining time per workpiece to be significantly reduced. This software is integrated into the existing control programme and applies the data from this for the machining process. During the first cut, iCut “learns” the idling output of the spindle and the maximum cutting efficiency per cut. Subsequently, it measures the spindle output up to 500 times per second and automatically adjusts the feed in each case. This means that the machine always operates at the maximum possible feed for each tool. Should the cutting conditions change (depths of cut, machining allowances, wear, etc.), iCut adjusts the speed and output in real time. This not only has a positive effect on the machining time for the workpiece, the optimised milling characteristics also increase the process reliability. The forces acting on the spindle are more constant and this also results in a longer service life.
If the tool is in danger of breaking, iCut reduces the feed straight away or stops the action altogether.
Florian Böpple, Digital Solutions Manager at Walter, says, “We have already achieved astonishing increases in efficiency for customers using iCut. If the machining operation is compatible, a 10% reduction in machining time is always achievable. We have already managed to reduce machining times by double this amount. When the quantity is high, this frees up considerable machine capacity.”
In addition, this works irrespective of whether Walter tools are used; all that is necessary is for the machine’s system requirements to be met.
Milling with ‘Xtended Technology’
Walter recently showed the potential of the tools themselves with the entirely new generation of Xtra·tec XT milling cutters. They combine design improvements with high-performance cutting tool materials. This means that the focus is always on increased productivity and process reliability. The most striking design feature is the installation position of the indexable inserts, at a greater incline and with a larger contact surface. This reduces the surface pressure in the seat while increasing the stability. The larger screw hole cross-section stabilises the indexable insert and the longer screws hold it in place more securely. The cutter body has also been made stronger, now with much more material behind the insert seat.
Besides increased process reliability, the special installation position of the inserts also allows for the addition of an extra tooth, thereby increasing productivity. The precise 90 deg shape of the shoulder milling cutter helps to reduce what would otherwise be additional required finishing operations. Clamping screws which are easier to access optimise handling and help prevent assembly errors.
Another new feature, which applies to the face milling cutter M5009, is the smaller indexable inserts which can be fitted to the milling cutters. These continue the current trend towards reduced machining allowances. The M5009 milling cutters combine small depths of cut with the economic advantages of double-sided indexable inserts—with eight usable cutting edges rather than the usual four. Thanks to these cutting edges, as well as a reduced number of finishing operations, the milling cutter achieves increased efficiency.
Our innovation also extends to sustainability. As part of Walter Green, the production and supply chain of the Xtra·tec XT milling cutters is CO2-compensated.
The four examples illustrate where we are heading in the metalworking industry—with respect to tools, machining strategies and the field of digital innovation. At the same time, they highlight four approaches showing where the opportunities lie and how the trends and challenges of the future can be dealt with successfully.
Preventing unscheduled downtime is one of the most effective cost reduction measures in any production environment. Mitsubishi Electric is offering practical solutions for both machine tools and robots.
Mitsubishi Electric and its [email protected] Alliance partner Lenord + Bauer have developed an advanced condition monitoring system for machine tools. It utilises smart encoders and a direct communication interface within Mitsubishi Electric machine controllers, such as CNCs, for accurate status information that is easy to access.
Operating hours are recorded and monitored along with temperature, speed and position by the Lenord + Bauer MiniCODER range. These parameters are then used to help schedule maintenance activities by providing an early warning message when component servicing or replacement are required. The ferromagnetic measuring gear and scanning unit can record speeds of up to 100,000 revolutions per minute, making the system ideal for feedback on machine tool spindles and positioning systems.
The second solution on the stand uses AI to increase the effectiveness of predictive maintenance. The cloud-based solution using the AI platform within IBM Watson analyses operational data and can optimise maintenance regimes based on actual usage and wear characteristics. It can be applied to robots and other equipment such as machine tools. Both smart solutions demonstrate how predictive maintenance for machine tools and robots can reduce operational costs, increase asset productivity and improve process efficiency.
70 companies from ten countries have connected 110 machines and 28 value-added services at EMO Hannover 2019 via the umati standard interface. “umati is opening up a new chapter in production,” says Dr. Heinz-Jürgen Prokop, Chairman of the VDW (Verein Deutscher Werkzeugmaschinenhersteller – German Machine Tool Builders’ Association), at the umati press conference on 16 September 2019 in Hanover.
“The interface enables machine tool manufacturers to fulfill another Industry 4.0 promise: the simple, fast and secure exchange of data,” continues Prokop. Creating a connection and providing a uniform language for machines, systems and software are essential prerequisites for reaping the benefits of digitalisation in production. The fact that individual companies no longer have to concern themselves with the correct functioning of the network interconnection represents a tremendous step forward.
umati has also already made a strong impression internationally. Three international consortia from major machine tool manufacturing countries have joined the interface: ProdNet from Switzerland, Edgecross from Japan and NCLink from China. In addition, the machine tool associations from China, the United Kingdom, Italy, the Netherlands, Austria, Switzerland, Spain and Taiwan as well as the European machine tool association Cecimo are supporting the project.
“Choosing the OPC UA standard as a basis for the development of the interface supports international dissemination. It ensures that umati can be used free of charge worldwide,” explains Prokop. 90 companies are contributing to the standardisation work in the Joint Working Group together with the OPC Foundation. The release of Version 1.0 of the Companion Specification, the next milestone, is planned for the middle of next year.
EMO showcase demonstrating the effectiveness of umati
The showcase at EMO Hannover 2019 demonstrates that the interface is already up and running. Each machine has an OPC UA server which sends the data to a data hub which has been set up especially for the trade fair. There, the software value-added services can access the data via OPC UA clients and show what added value can be generated from the resulting data. How the data is coming together can be experienced via a live dashboard at the umati central information booth (E24) in Hall 9.
umati success will be decided by the market
Whether or not umati is successful will ultimately depend on how customers rate the added value of the interface. For their part, manufacturers must provide this added value in a dependable manner. “For this we need reliable partners who can provide the necessary components such as control architecture and software components. We will achieve this through close cooperation with the control manufacturers and, in future, no doubt also with extensive parts of the supply chain,” says VDW Chairman Prokop.
But until then, the umati working group still has much to do. Version 1.0 will be the starting signal for launching actual products. “In the future, the umati brand should represent a promise: anyone who buys a umati machine and has umati interface software should be able to get the data flowing with no difficulty,” says Prokop.
In order to achieve similarly extensive distribution to that of the USB connector in the consumer goods sector, the VDW is working – in addition to the Companion Specifications – on establishing a binding specification for the configuration of communication parameters, defining minimum requirements for implementation, and developing standardised test procedures to assess performance. Further aims include extending the brand’s global reach, defining binding conditions for its use and setting up a viable organisational structure. “Version 2.0 is already on the horizon because there are many aspects which have not yet been tackled, such as production order management on the machines, or tool management,” concludes the VDW Chairman.
Andreas Scheuer, Federal Minister of Transport and Digital Infrastructure, opens the world’s leading trade fair for metalworking
Carl Martin Welcker
Andreas Scheuer, Federal Minister of Transport and Digital Infrastructure, together with Lower Saxony’s First Minister Stephan Weil, Member of the Board of Management of Deutsche Telekom Adel Al-Saleh, Cecimo President Dr. Roland Feichtl and EMO General Commissioner Carl Martin Welcker, is opening the EMO Hannover 2019, the world’s leading trade fair. For six days, Hanover will once again become a Mecca for the international production technology industry. The theme of the event is “Smart technologies driving tomorrow’s production!” and more than 2,200 exhibitors from 48 countries are set to present their innovations for industrial production.
“Digitalisation and networking have been the subject of much discussion over the last few years, but they are now finally being implemented in the production processes,” says Carl Martin Welcker at the opening press conference in Hanover. Factories are becoming smart, machines and tools are becoming intelligent. They communicate with each other and are raising production to new quality levels. Many exhibitors are showcasing offerings for this. There are over 2,000 hits for the term “Industry 4.0” on the EMO website alone.
EMO Hannover presenting solutions to mega issues
Welcker sees major challenges and opportunities arising from the transition of the automotive industry – the sector’s largest customer. “Electrification will not happen overnight. Rather, there will still be many optimised fossil fuel-powered vehicles on the road, either with pure combustion engines or hybrid drives,” he said. The introduction of new drive technologies will undoubtedly lead to changes in individual manufacturing processes. However, the EMO General Commissioner strongly believes that highly differentiated solutions must be found to meet the highly disparate needs of cars, commercial vehicles, motorcycles, aircraft, marine engines, mobile machines and e-bikes. If we are to achieve the ambitious CO2 climate targets, it is all the more important to redouble our efforts in the search for future drive technologies, and to ensure that the best solution prevails in each case.
Researchers at FEV Consulting have calculated that fully electric vehicles will have a 19 percent share of the global market by 2030. This relates to 118 million new registrations, the overall number of which is not expected to change significantly from the 2017 figure. They also speak of a 64 percent reduction of the added value in the manufacturing process for pure electric drives, and 24 percent higher added value for plug-in hybrids.
In this scenario, any losses in production can potentially be compensated by new requirements. Improvements to the efficiency of the remaining combustion engines and transmission systems in the form of optimised surfaces, the reduction of noise emissions, protection against component wear (which is more intense in hybrids due to the switch from electric to combustion mode at high speeds) and the redesign of braking systems (required due to the high battery weights): all these factors call for new or modified production processes. In addition, there is the installation of rapid charging facilities nationwide. Complex new production systems are also needed for the manufacture of key electrical components such as batteries, traction motors and power electronics.
Sustainability is the basis of the machine tool industry’s business model
Without the use of intelligent technology, it will not ultimately be possible to achieve the ambitious climate protection targets by 2030. In any consideration of such advances, the focus is always on industrial production and thus on machine tools as ‘enablers’. There are demands for lower energy and material consumption levels, higher process efficiency coupled with higher product quality. “In fact, the tool industry is making a major contribution, because its business model is centred squarely on efficiency and waste avoidance,” points out Welcker.
The industry would not enjoy such international success if it was not capable of processing ever new materials – such as lightweight construction in the automotive industry – and of establishing more energy-efficient processes by cutting out entire processing steps, e.g. by combining a number of processes in a single machine. Industry 4.0 is currently giving rise to much talk about ‘digital twins’. These allow optimised machines, components and processes to be designed on the computer before any actual materials are used in production. Power generation, whether conventional or regenerative, ultimately requires sophisticated production technology, too. This is crucial if sustainable principles are to be adhered to in the necessary machining of large parts for wind turbines, in combined heat and power generation, or in the laser machining of solar panels. This is at the heart of what the machine tool industry stands for.
Sustainability has always been a key factor in the construction of the machine tools themselves. The machine tool industry fulfilled the EU’s requirements as part of its move towards establishing a circular (closed-loop) economy long ago: energy- and resource-efficient production, long service lives, incentives for refurbishment, updatability of control systems, second and third lives for products. This makes it an ideal example of how to implement recycling management.
Decline in German machine tool production expected in 2019
“EMO Hannover 2019 is taking place in less than ideal economic circumstances,” admits Welcker. After eight strong years for the machine tool industry, global demand for capital goods has been in decline since the fourth quarter of 2018. User demand in all regions of the world declined significantly in the first half of 2019. In the EMO host country of Germany, incoming orders also fell by more than a fifth in the first six months. Therefore VDW (German Machine Toll Builders’ Association) revised the production forecast for Germany to minus two percent.
However, a leading world trade fair such as EMO Hannover can reveal at an early stage the technologies which are likely to attract investment in the future. New offerings arising from digitalisation and the introduction of artificial intelligence, new products made possible through the extensive use of generative processes etc. will open up new dimensions of efficiency and quality in production. Companies should now be getting themselves in shape for the coming years – through strategic realignment, modernisation of production, increased process efficiency. “There are many potential approaches. The solutions will crystallise in the coming days, not least here at EMO Hannover,” says the EMO General Commissioner.
The optimum machine tool combined with the optimum tool results in a perfect combination. And that makes cost-effective processes and impressive machining results possible. Article contributed by MAPAL.
Figure 1: Dietmar Maichel (left), project manager 3D milling at MAPAL, and Steffen Nüssle, sales director export and head of applications engineering at Zimmermann, in front of the FZH horizontal machining center (HMC).
The optimum machine tool combined with the optimum tool results in a perfect combination. And that makes cost-effective processes and impressive machining results possible. One good example of this is the cooperation between machine manufacturer F. Zimmermann GmbH and MAPAL.
F. Zimmermann developed its first horizontal machining centre (HMC) especially for the machining of structural parts for the aerospace industry. The aluminium structural parts, such as wing parts and frame ribs, are generally milled from solid material—with up to 95 percent material removal.
Fault-free machining with respect to dimensional accuracy and surface finish is crucial here. And the component structure that becomes more and more delicate with increasing material removal represents an additional challenge.
In order to make the milling process as efficient as possible even in these areas, Zimmermann has developed the FZH machining centre that offers maximum rigidity and features a robust, water-cooled travelling column. Whereas conventional machine concepts suffer from lever-related deviations with increasing slide, the guide carriage distance of the FZH increases with increasing plunging depth into the material.
In order to achieve maximum efficiency, Zimmermann employs its own patented M3ABC three-axis milling head in the machining centre, especially in the pocket corners of a workpiece. This milling head has to perform only very small swivel movements, allowing the feed rate to be kept constant and hence, the machining time to be significantly shortened.
At an open house in June 2017, Zimmermann demonstrated its machining centre with tools from competitors. These tools failed to meet the expectations, however, and were unable to exploit the performance of the machine.
“Why not test the performance of the MAPAL tools?” thought the project managers at Zimmermann, as MAPAL was presenting its milling cutters for high-volume machining at the event. A short time later, representatives of the two companies carried out extensive milling trials with different tools together.
Figure 2: MAPAL tools used at Zimmermann (from left to right): SPM-Rough ISO shoulder milling cutter with indexable inserts as roughing solution for diametre ranges above 25mm; SPM-Rough solid carbide milling cutter with wave profile as roughing solution for diametre ranges up to 25mm; OptiMill-SPM solid carbide milling cutter for multi-stepped semi-finishing of thin-walled structures; and SPM-Finish solid carbide milling cutter for finishing of deep pockets and delicate structures in a single pass.
The Milling Cutters
“Our goal was to choose the optimum tools from our portfolio for the machining operations on the Zimmermann machine,” explains Dietmar Maichel, project manager 3D milling at MAPAL. The tool manufacturer’s portfolio contains different milling cutters for the different tasks during the high-volume machining of aluminium structural parts. The tools are perfectly designed for use on such high-performance machines as the Zimmermann machine.
In particular, the SPM milling cutters, which are available in a solid carbide design and with PCD and ISO inserts, are being used today—a total of four tools, to be exact—at Zimmermann for the different demands of the roughing and finishing operations.
“The perfect combination of the machine, the three-axis milling head and the tools from MAPAL give the user a real performance boost,” says Steffen Nüssle, sales director export and head of applications engineering at Zimmermann, immediately after the first tests. “With the SPM-Rough ISO shoulder milling cutter, we achieved the best results that we have ever achieved with a tool with indexable inserts.”
The ISO tools with polished indexable inserts are the latest addition to the MAPAL SPM product range. The SPM-Rough with wave profile also surpassed the expectations for material removal with excellent smooth running.
“The complete machining of a 190x190x40 mm pocket is now effectively possible in less than a minute,” explains Nüssle.
The experts at F. Zimmermann are convinced by the MAPAL tools. “The use of the SPM milling cutters has given us a quantum leap forward in the aluminium machining. And it shows us what the perfect combination of tool and machine means in terms of performance,” says Nüssle. The tools are the first choice when it comes to machine acceptance tests or demonstrations for customers from the aerospace industry at Zimmermann.
The Zimmermann machines are suitable not only for the machining of metals. “Many of our customers manufacture parts of composite materials,” says Nüssle.
Zimmermann, therefore, also wants to mill trial parts of these materials using MAPAL tools.
“We are optimistic that with the MAPAL milling cutters for composite machining, we will also find a new secret weapon to exploit the performance of our machines even better,” says Nüssle. The corresponding plans are already in hand.
Vietnam mechanical industry is predicted to be a potential sector to catch up with the sustainable development of worldwide industry in the fourth industrial revolution. Being along with this industry through years, MTA is supposed to be the Vietnam premier trade event for Precision Engineering, Machine tools and Metalworking. The exhibition is held on July 2nd – 5th, 2019 at Saigon Exhibition and Convention Center (SECC), promised to display a strong line-up of cutting-edge products together with different interesting additional activities.
Vietnam Mechanical Industry Are Gradually Affirming Its Position In Industrial Revolution 4.0
As Vietnam powers past the first half of 2019, its growth remains stable within the context of slowing global economic growth faced with increasing challenges, contentions and risks. At the end of 1Q19, Vietnam’s GDP growth reached a commendable 6.8 percent, with the industrial and construction sectors contribution at 8.6 percent – the highest rate amongst all key Vietnam industry sectors. The industrial sector looks set to lead GDP growth over the near term as Vietnam has maintained her appeal for foreign direct investment in the manufacturing and industrial sectors.
While the world is progressing to the fourth industrial revolution, manufacturing level of Vietnam industry is still at the first stages and limited by new technologies, information, skill and infrastructure. However, if the enterprises know how to take the advantages of opportunities and are facilitated to develop, Vietnam mechanical industry is predicted to be a potential sector to catch up with the sustainable development of worldwide industry in the fourth industrial revolution. Besides, mechanical enterprises should actively renovate their technologies and collaborate with different partners to maximise the efficiency in working. With strong supporting and beneficial policies from the government and associations, the new industrial era would be easier to reach.
MTA Vietnam 2019 – Catching Up With Worldwide Industrial Innovation
MTA Vietnam makes it return as 17th edition and has asserted its position for the last 16 years as the premier precision engineering, machine tools and metalworking exhibition in Vietnam which meets the innovative demands of global tendency. With exhibition area is expanded to Hall A3 and reaches 13,900sqm, the event will showcase a number of industrial products serve for precision engineering, machine tools and metalworking industry provided by different suppliers from around the world. This year’s event attracted more than 514 exhibitors from 22 nations and regions with popular labels such as: Amada, Beijing Jingdiao, Bystronic, Cybertech, Dine Vina, Hypertherm, Hwacheon, Jinan Bodor, Knuth, Mazak, Marposs, Mitsubishi, Muratec, Nikon, Shandong Leiming, Sandvik, Sodick, Renishaw, Takamaz, Trumpf, Van Su Loi, Viet Vu, VPIC Viet Phap, Yamada,… and many others.
MTA Vietnam 2019 honourably welcomes 14 international group pavilions from countries with strong technological development such as: United Kingdom, Taiwan (3), Germany (2), Korea (5), Japan, Singapore and Thailand. Taiwan group pavilion has the biggest exhibition area with over 60 exhibitors attend. Korea is the nation that attracted the most associations with five international group pavilions include more than 50 companies to come and promote their products. Besides, United Kingdom is a brand new international group pavilion which is established for the first time in Vietnam, with supporting from Engineering Industries Association (EIA).
A place to exchange knowledge about science and technology
Technical seminars and conferences are alongside activities which attracted a plenty of visitors at MTA Vietnam. With the topic entitled: “New trends of metal forming technology”, technical seminar is hosted by the organiser: Informa Markets Vietnam and prestigious speakers from top-rated businesses such as: Dr. Ngo Cong Truong, Founder and Professional Director, John&Partners JSC; Mr. Pham Duc Hiep, Sales Manager, Trumpf Vietnam Co., Ltd; Mr. Garry Chuang, Sales General Manager, Bystronic; Mr. Hoang Minh Dong, Manager, Amada Vietnam Co., Ltd and Mr. Naoya Ogawa, Area Manager of ASEAN and Oceania, Murata Machinery Ltd.
Multi Engineering Solution Laboratory – MES LAB has continually accompanied with the seminar series at MTA Vietnam and brings the topic titled: “PRODUCT DESIGN & DEVELOPMENT – PROCESS AND TECHNIQUES TO IMPLEMENT FOR R&D AND INNOVATION TEAM”, conducted by Dr. Tran Anh Tuan (CEO MES LAB) and MES LAB Team. The program is hoped to bring interesting sharings about product design & development process by new technology.
Experiencing our industry 4.0 introducing booth called: “We are Industry 4.0 ready!”
This booth is opened with the aim to introduce products reach industrial 4.0 standard from the exhibitors. With the criterion: “Nine pillars of Technological Advancement that forms the basis for Industry 4.0”: Big Data and Analytics, Autonomous Robots, Simulation, Horizontal and Vertical System Integration, The Industrial Internet of Things, Cybersecurity, The Cloud, Additive Manufacturing, Augmented Reality (Source: Boston Consulting Group 9/4/2015), the products which have one of above standards will be displayed at this special booth. Through short videos and introduction, this is supposed to be a chance for the exhibitors to approach visitors more effectively.
This special booth welcomes 22 popular brands such as: 3D Smart, Amada, Bejing Jingdiao, Cybertech, Kita Sensor, Mazak, Nam Sơn, Nikon, Siemens, Trumpf, Woosung, ZWSOFT,… and many others to attend and showcase their products.
Under the motto “German High Tech in Metal Working”, around 50 German companies will present themselves at Metalex, the largest metal-working trade fair in the ASEAN region. Top German companies such as Alfred H. Schütte GmbH & Co. KG, Gebr. Heller Maschinenfabrik GmbH, Gühring KG, MAPAL Fabrik für Präzisionswerkzeuge Dr. Kress KG and Siemens AG will take part in the sector event from 20 – 23 November 2019. Dr. Wilfried Schäfer, Director of the VDW (German Machine Tool Builders’ Association), says: “Thailand is the most important market for the machine tool industry in the ASEAN region, with great potential for production technology. There is keen competition in the market, especially from Japanese companies. So we are all the more delighted that Germany is the partner for Metalex, and our firms will be able to present their innovative potential there with a sector event.”
For Exhibitor President Andrew Parkin, Gebr. Heller Maschinenfabrik GmbH, the great interest on the part of German companies in the south-east Asian market is no coincidence: “Metalex provides the numerous exhibitors with the opportunity to meet both competitors and potential customers at an event. Thailand and south-east Asia are often underestimated with regard to their market potential. However, the markets in south-east Asia continue to develop positively in accordance with our expectations, and will increase in importance for globally active machinery manufacturers also in the future.”
Special Show On Umati To Present German Cutting-Edge Technology
The nomination of Germany as partner country at Metalex underlines the significance of German companies for the worldwide machine tool and machine construction industries. Exhibitor President Andrew Parkin confirms: “The quality seal “Made in Germany” still carries great weight in the region of south-east Asia. For us and the many visitors, this sector event is an outstanding platform for discussing current manufacturing requirements, developments and trends, and for laying the foundations for investments. We expect to make new contacts and thus develop business opportunities in Thailand and south-east Asia.”
Within the framework of the sector event, the special show umati will present the future of the industry.
umati (universal machine tool interface) is a universal interface that can integrate machine tools and plants safely, seamlessly and effortlessly into customer- and user-specific IT eco-systems. This standard will not apply only in Germany, but will be available for users around the world. umati is an initiative of the VDW and 17 project partners, of whom the founding members CHIRON-WERKE GmbH & Co. KG, Gebr. Heller Maschinenfabrik GmbH, GROB-WERKE GmbH & Co. KG and Siemens AG will be taking part in the special show in Thailand.
Germany will be the partner country at Metalex in Bangkok, the biggest metal-working trade fair in the Asean region. From 20 – 23 November 2019, upon the initiative of the VDW (German Machine Tool Builders’ Association), the German Federal Ministry of Economics and Energy (BMWi) and the exhibition and trade fair committee of the Association of the German Trade Fair Industry (AUMA) will organise a sector event within the framework of the partner country participation of Germany. Under the motto “German High Tech in Metal Working”, German machine tool manufacturers and companies from the metal-working sector will present themselves to the Asian specialist public on a surface area of around 1200 square metres. In addition to the joint stand, the sector event will also offer a special show with machine demonstrations and a presentation forum.
You will find all information on the sector event and contact details for the organising company Messe Stuttgart here.
Network your production with TNC controls! Designing in the CAD system, programming and preparation of the production data in the CAM system, simulation of machining on a virtual machine, tool preparation, tool measurement, tool management – all this has long been available in modern manufacturing. Article by Heidenhain.
However, the smooth exchange of data between all persons and systems involved is in no way a matter of course. Here a lot of manual work is still on the agenda—in a better case a manually initiated data transmission, in the worst case the passing on of handwritten notes.
The Machine Tool As The Focal Point In The Workshop
The workpiece is made on the machine, so all information must come together here. And from here, crucial information about the status and quality of a workpiece must also flow back into the IT systems of production—i.e. into the process chain. The machinist responsible for the quality of the components and for staying on schedule must have access to all the data and must be able to apply his experience in manufacturing to the process chain.
There are many ideas for the networking of all persons and systems involved in the process. But under these considerations, making the machine control in the workshop the focal point of a company network has a very special charm.
Current Tool Data Always And Everywhere
The fixed blanks are lying on a pallet at the machine for pending work. Calibrated tools are already loaded in the machine’s tool magazine. They are clearly identified by a code on the tool holder. The TNC operator used a scanner to read this identification when he loaded the tool magazine, so the TNC 640 knows which tools are available in the machine. The data comes directly from the tool management over the Heidenhain DNC interface.
Using the Remote Desktop Manager, the TNC operator can directly access the CAM system from the TNC 640 control. For its part, the CAM system returns to the tool database for program creation. Using the Batch Process Manager of the TNC 640, the TNC operator can now schedule execution of the production job on the machine. In the Batch Process Manager, NC programs and the position of the clamped workpiece on the pallet are linked with respect to the order and sorted into the list of open orders by priority.
The Batch Process Manager enables the TNC operator to schedule several production orders simultaneously. The control supports this by once again comparing the tools used in the NC program with the tools actually available on the machine. The control then reports any tools that are missing, and states the estimated machining time. The TNC operator can then, for example, output a list of tool differences: this list contains only those tools that still need to be prepared.
The information about the estimated machining time can also be used for further order planning, such as subsequent jobs for the machine or the further logistics of the finished parts. This information is also used together with information from the tool management to order new tools. The new StateMonitor software supports the TNC operator in this regard. StateMonitor captures the data of connected machines, presents a real-time view of the machine status, and can send messages to computers throughout the company as well as to mobile devices. StateMonitor also uses the DNC interface.
The tool preparation station then immediately receives orders for any additionally required tools. This also applies to series production runs that are currently underway. StateMonitor can send a message to the tool preparation station if a tool’s age is approaching a critical value and this is detected by the NC program. Based on the data stored in the tool management, the tool preparation station can then promptly prepare new tools in the tool presetter for calibration. In this case as well the data of the exact tool settings are sent to the tool management. The pre-set tools are given their own code on the tool holder for unambiguous identification. The CAM program and the virtual machine then also have access to this exact data.
The final, automatic workpiece measurement on the machine delivers important data for quality assurance. This data can simply be archived or it can be evaluated. Naturally the data is also centrally available to all other systems, meaning that from the NC program to the tools, all links of the process chain can be optimized.
Connected Machining: Flexible connections for individual circumstances
The core components of Connected Machining are the Heidenhain DNC interface, the Remote Desktop Manager, and the StateMonitor software. The Heidenhain interface establishes the connection to enterprise-resource planning systems and production-activity control systems, and also links StateMonitor to the company network, whereas the Remote Desktop Manager provides access to all Windows applications. Also, numerous useful functions for data presentation, such as viewers for PDFs and graphic files as well as for CAD files in STEP or IGES format, are a standard feature of TNC controls from Heidenhain. A browser is also installed on the control. All that’s left is to simply connect the control to the company network over an Ethernet connection.
The solutions provided by Connected Machining are universally adaptable to the individual circumstances of a production department, meaning that every company can design its process chain according to its own needs and desires. The various functions and software solutions thus link the production department to a process chain with a uniformly digital flow of information. This can be done completely independently of the solution chosen, regardless of the respective downstream systems. Our goal is the greatest possible flexibility for our customers. They can adapt, configure, and implement the solutions from Heidenhain themselves.