Traditionally DMG MORI showcases a cross-section of the most innovative technologies when the AMB opens its doors to trade visitors from all over the world. With around 30 exhibits from the fields of turning, milling and advanced technologies on an exhibition area of over 2,000 m² the machine tool producer will be giving visitors a glimpse into the future of production from 13^th to 17^th September 2016. The innovations on show during the trade fair will include the third generation DMU 50, for example, and the Robo2Go automation solution – this can be used on several machines without any knowledge of robots.

DMG MORI Software Solutions – Products and solutions for digital transformation

A key building block in DMG MORI’s customer-oriented digitalisation strategy is the app-based CELOS system, that the machine tool manufacturer first presented around three years ago and which it has consistently continued to develop in a targeted manner ever since. Using this uniform user interface for machine and office PC, employees in shop floor and job scheduling can manage, document and visualise all job order, process and machine data. Thanks to its open architecture, CELOS allows the exchange of information with higher–level structures in addition to the impact it has in the shop floor area. So CELOS offers customers complete integration of their machines in the company organisation while simultaneously creating today the interface of metal cutting production in the cyber-physical production system of the future. The benefits in day-to-day operation are convincing: a 30 percent time saving in tooling times and 50 percent less time and effort for the calculation of technology values or the search for important information are just a few of the effects that can be achieved with CELOS. Customers also profit from the continuous further development of the CELOS system, because with every new release DMG MORI implements 50 enhancements. In addition, DMG MORI will be presenting ten new CELOS APPs at the AMB. These will include the new CELOS DEVELOPER APP, with which partners will be able to develop their own APP for the very first time.

Workshop-oriented programming is still of great importance, especially in single item production and the production of small and medium-sized quantities – and it will remain just as important for a long time to come. Working with cycles is state of the art in this respect and the reason why standard cycles in turning, milling and drilling have long been part of the scope of performance of modern controls. Based on its decades of application experience DMG MORI has gone far beyond the standard and currently has 24 exclusive DMG MORI technology cycles for the fields of turning / turning-milling or rather milling / milling-turning in its portfolio. These enable operators in the workshop to programme even complex machining tasks themselves directly on the machine via a dialog using parameterised context menus up to 60% faster. Outstanding examples here include the machining of free-form surfaces using 5-axis interpolation or various cycles for gear cutting or gearwheel production. Other cycle highlights include the MPC (Machine Protection Control) for the protection of machines, workpiece and tool, the 3D quickSET toolkit  for checking and correcting the kinematic accuracy of 4 and 5-axis machines or the Application Tuning Cycle for the process-oriented tuning of feed drives in relation to the table load at the push of a button.

World premiere: DMC 160 U duoBLOCK– maximum productivity in heavy-duty machining

DMG MORI has always responded to growing demands on components with future-proof CNC technology. The latest example of this is the new DMC 160 U duoBLOCK, which will be available as of this year’s AMB. The 5-axis universal machining centre with pallet changer is based on the proven duoBLOCK principle and in its 4^th generation offers 30 percent more stability and accuracy while at the same time reducing energy consumption by 30 percent. Innovative highlights of the world premiere include the new 1,800 Nm 5X-torqueMASTER gear spindle and a travel path in the Y-direction that has now been lengthened from 1,250 to 1,600 mm.

Heavy-duty machining is now part of routine work in the field of mechanical engineering generally – in the aerospace branch, for example, or the automotive industry for the production of chassis parts and engine blocks. In this respect the sturdy construction of the patented duoBLOCK concept offers the perfect basis for both productive and high-precision machining on the DMC 160 U duoBLOCK. Its extensive cooling measures in the machine bed and base plus its wide linear guides, drives and the spindle also boost the long-term accuracy of this universal machining centre. The pallet changer of the DMC 160 U duoBLOCK can handle workpieces weighing up to 4,000 kg, while travel paths of 1,600 x 1,600 x 1,100 mm mean the workpieces can also have extremely large dimensions.

World premiere: 2^nd Generation DMC 210 U– productive heavy-duty machining with pallet changer

Maximum rigidity and long-term accuracy have always been the outstanding features of the portal machines from DMG MORI. The machine tool manufacturer has optimised these even further in the second general of this successful series. With a large cube-shaped work area and a high-performance spindle programme plus CELOS in the standard version, the new DMU 210 U is perfectly equipped for the rising demands on the market. Thanks to its numerous equipment options this machine, which will be available just in time for the AMB, is ideally suited for mechanical engineering in general and in particular for sectors such as tool and mould making and aerospace. The large cube-shaped work area with travel paths of 2,100 mm in the X and Y directions and 1,250 mm in the Z-axis offer ample space here.

The fast and innovative wheel magazine can hold up to 303 tools (SK50 / HSK-A100) with lengths of maximum 900 mm despite its minimum space requirement. The standard chain magazine has 60 tool pockets and offers the option of holding a 30,000-rpm pick-up motor spindle. With a torque of 1,800 Nm, 52 kW output and 8,000 rpm the 5X torqueMASTER is a special highlight among the other available spindles. Thanks to its extended swivel range and optimised interference contour, this gear spindle enables the heavy-duty machining of complex 5-axis components. In addition to its equipment and performance, DMG MORI has also improved the efficiency of the DMU 210 U thus reducing energy costs and making a significant contribution to environmental friendliness.

DMU 90 P duoBLOCK– heavy-duty machining with an attractive package price
5-axis machining of the highest level is also the trademark of the fourth generation of the successful duoBLOCK series. Outstanding features here include the highly stable design of the universal machines, long-term accuracy and highest precision with up to 4 μm positioning accuracy even in the standard version. With its DMU 90 P duoBLOCK DMG MORI now presents a machining centre that will continue the triumphal march of the series. This latest model is designed as a package machine with a 430-Nm and 52-kW motor spindle, space for 60 SK50 tools plus an IKZ coolant unit and guarantees an economical entry into heavy-duty machining.

The DMU 90 P duoBLOCK allows an economical entry into heavy-duty machining.

Applications in tool and mould making as well as in general mechanical engineering call for investment in reliable, high-performance production equipment. DMG MORI has included the attractively priced DMU 90 P duoBLOCK in its range with universal machining in mind. With an X-axis travel path of 900 mm and a workpiece weight of 1,800 kg, it outperforms the smaller DMU 80 P duoBLOCK. Where its technical equipment is concerned, DMG MORI has concentrated on heavy-duty machining and offers the DMU 90 P duoBLOCK^® as an appropriately equipped package machine.

Yamazaki Mazak is taking 12 machines to AMB 2016 in Stuttgart, exhibiting the full breath of its machine range and new SMOOTH Technology, the world’s fastest CNC.

The Mazak stand, which is themed ‘It’s all about you’ in recognition of the company’s continued focus on developing machines which solve specific machining challenges faced by its customers. The Mazak stand will showcase horizontal and vertical machining centres, 5-axis machines, turning centres, a new machine from its entry-level range and, for the first time at a German show, all three variants of the company’s new SMOOTH Technology, namely SmoothX, SmoothG and SmoothC control.

The highlight of the show is likely to be the new INTEGREX i-400 AM, a revolutionary hybrid machine which combines additive manufacturing with multi-tasking capability. The i-400 AM integrates Direct Energy Deposition additive manufacturing technology into a 5-axis multi-tasking machine to offer machine users unrivalled hybrid technology and subtractive manufacturing in one platform.

The INTEGREX i-400 AM makes use of a built-in 1kW fiber laser to melt metallic powder, which is then applied layer-by-layer via interchangeable cladding heads. The heads are stored in the machine’s standard 36-tool magazine and enable the automatic change from additive to subtractive tooling, optimising process cycle time.

The INTEGREX i-400 AM technology can be used to clad a range of material types, including stainless steel, nickel alloys and copper, making it ideal for a range of applications, from repairing existing worn or damaged components or the complete generation of new parts. The machine is equipped with SmoothX control, the 5-axis version of Mazak’s new SMOOTH Technology, which enables the machine to efficiently process prismatic, round and highly contoured work pieces, as well as those near net features which have been created using the integrated additive technology.

Horizontal machining centres will be represented by the HCN 5000/50, a new 50 taper machine with a 500mm square pallet boasting extremely agile performance characteristics, including a 10,000rpm/ 37kW high performance spindle; rapid traverse rates of 60m/min in the X-, Y- and Z-axes; and a chip-to-chip change time of only 3.5 seconds. The 50 taper spindle provides a highly rigid interface for mounting large tools, up to dia. 320mm, enabling a high productivity solution for machining a range of components for automotive, agriculture, construction and the cutting of cast materials.

The machine has the smallest machine footprint in its class, with a floorspace-saving design and overall machine dimensions which measure only 2,544mm x 5,830mm. Importantly, the space-saving design has been achieved without compromising its machining performance and ability to handle large workpieces, with the HCN 5000/50 able to bear components up to dia. 800mm x 1,000mm in height. HCN 5000/50 is also available in a single pallet and A-axis table configuration with integrated hydraulic services, proving a well-designed solution for complex fixturing. The machine on display at AMB 2016 is equipped with the new SmoothG CNC and an 80 tool hive.

Also on the stand will be the VTC-800/30SLR, a new addition to the hugely successful European-designed and manufactured VTC800 vertical travelling column machine series, which is available in both 40 and 50 taper versions. The 800/30SLR incorporates a 1,000mm diameter rotary table capable of carrying a 2,200kg load, which makes it ideal for machining large components, along with a centre partition that enables the set-up and machining of a different component on the right side of the normal table.

The specific machine at AMB 2016 is equipped with a Siemens SINUMERIK 840D sl control for those machine users that have standardised on Siemens control in their operations. The SINUMERIK package includes CNC, Mazak spindle with fully integrated Siemens motor and SINUMERIK drives and servo motors.

Mazak will also exhibit its MULTIPLEX 6200-II Y turning centre, which is ideally suited to high volume applications, such as the automotive sector. The MULTIPLEX combines two NC turning centres with milling capacity and is capable of performing continuous and simultaneous machining by both spindles, including automatic workpiece transfer from one spindle to the other. The machine is equipped with a 5,000rpm main spindle and is capable of rapid traverse rate of 30,000m/min in the X-axis and 33,000mm/min in the Z-axis.

Entry-level machines remain a vitally important part of the Mazak range and AMB 2016 will showcase the new QT COMPACT. The COMPACT is a high specification, entry-level model boasting Mazak’s integrated spindle technology for the main spindle and Tool Eye as standard – which together offer both improved performance and accuracy. The QT COMPACT comes equipped with a Mazak manufactured driven tool turret and an eight-inch chuck. It is capable of a maximum speed of 5,000 rpm and a peak torque of 167 Nm. The machine is equipped with SmoothC control, incorporating state-of-the-art motion control technology.

Martin Engels, Managing Director for Yamazaki Mazak Deutschland GmbH, commented: “AMB has become one of the major European machining shows and we are delighted to be bringing 12 state-of-the-art machines to the exhibition, from the most sophisticated 5-axis and multi-tasking technology through to entry-level machines. All of the machines on display demonstrate our philosophy of focusing on our customers and devising solutions to the different machining challenges they face every day. I am particularly pleased to be exhibiting all three variants of our SMOOTH Technology for the first time at a German show and our new INTEGREX AM hybrid manufacturing machine, which combines additive and subcontract technology in one platform.”

Machining tools are becoming increasingly efficient. This is what the KOMET GROUP is demonstrating at AMB 2016, where the precision tools manufacturer is presenting numerous innovations under the trade fair slogan “TOTAL PRODUCTIVITY SOLUTIONS”. Highlights include the growing range of milling tools that can also be used in generative manufacturing processes, as well as a completely new indexable insert reaming tool and unique expansions of the KOMET KUB Pentron^® drill. Other attractions include the numerous innovations in mechatronic tools and ultra-hard cutting tool materials as well as the KOMET^® ToolScope assistance system, which bridges the gap from machining to Industry 4.0.

Renowned as a leading innovator in high-precision drilling, reaming and threading, the KOMET GROUP presented a significantly expanded range of milling cutters just last year that transformed the tool manufacturer into a single-source supplier. Alongside the KOMET^® solid carbide milling cutters for all requirements in the diameter range of 3.0 to 25.0 mm, the KOMET^® indexable insert milling cutters have primarily been subject to further improvements.

The cutter holders in the completely redesigned KOMET^® PCD milling cutters are manufactured using the generative process of laser melting, which means that these new tools can offer feed rates up to 50% higher than before. 3D printing enables up to twice as many cutting edges to be created – regardless of diameter. KOMET^® is also utilising the structural flexibility provided by the additive manufacturing process to create a perfect design for the course of the coolant channels inside these milling cutters. Curved channel routes now reduce pressure loss in the coolant and are positioned precisely in such a way that every cutting edge is supplied with coolant from a separate channel.

Aside from the new production process, KOMET^® is also expanding its milling range with new designs, such as the KOMET^® hi.aeQ 45° face-milling cutter, which has a feed rate of up to 40% higher than a shoulder milling cutter. KOMET^® is also launching new PCD milling and thread milling tools to standard versions that can be particularly productive when used in applications involving lightweight construction materials.

Dimensionally accurate – even for large drilling depths

For years, the KOMET KUB Pentron^® solid drill has stood for precise drilling under extreme conditions. This tool was previously only available in the 4xD and 5xD length/diameter ratios, but the Besigheim tool specialists have now also developed 2xD and 3xD versions so that the high-performance indexable insert drill can be used in an even more versatile manner. The CS (Custom Solution) variant has drawn particular attention with its diameter/length ratio of 6xD. As a result, the KOMET KUB Pentron^® CS, which has been optimised for Key Account and industry segment requirements, does without guide elements and is extremely competitive compared to its guided counterparts on the basis of its performance data.

Indexable insert reaming: Simplified index exchange
Indexable insert technology has revolutionised reaming with multiple cutting edge reamers and has set new standards in terms of cost efficiency and functionality. The KOMET GROUP has now successfully developed new high-precision indexable insert reaming tools that are even easier to operate. In previous tools, each insert was assigned a specific insert seat identified by the letters A, B, C, etc., but this positioning has now become redundant. Users can fit the indexable inserts into the new KOMET^® indexable insert reaming tool in any order – making errors virtually impossible and reducing the logistical effort required.

Increase in performance with diamond cutting materials
As already mentioned with milling, the KOMET GROUP is focussing on developing tools with ultra-hard cutting materials. One example of this is the expansion of the range of ISO indexable inserts with diamond cutting edges to a total of more than 900 items. In addition to KOMET^® PCD products, CVD thick film diamond-tipped inserts can now also be supplied. All variants are manufactured using the latest production technology, such as laser machining and high-vacuum soldering, which results in high-quality cutting edges and variable geometries as well as improved cutting results and longer tool life.

Facing head with direct position measuring system
Mechatronic tools such as precision adjustment heads, facing heads and the KomTronic^® U-axis systems, available in several variants, are one of the specialities of the KOMET GROUP. A patented direct encoder has been available as an optional extra for U-axes and the purely mechanical KomDrive facing heads for two years. In order to enable encoding to take place directly on the slider, the encoder also takes disturbance variables of mechanical elements into account, such as the drive element tolerances, the temperature range and wear. The control system can respond to the measurement data immediately, providing accuracy to +/- 3 µm and thereby enabling outstanding machining quality to be achieved.

Tool and process expertise from a single source
KOMET BRINKHAUS GmbH has been part of the KOMET GROUP for more than three years. As a result of the interaction between tool experts and process monitoring specialists, it has been possible to further develop the ToolScope process monitoring system into an integrated assistance system in terms of Industry 4.0. It monitors the internal signals from the machine, detects events such as tool changes or machine stoppage and is able to calculate parameters and deduce trends. At AMB 2016, KOMET^® is demonstrating how easy ToolScope is to use: Customers can select the solutions they require from the broad range of applications – from tool monitoring to an automatic tool change log through to adaptive feed control – and license them individually. Operation of the system has also become more flexible: Users can now view and operate their custom assistance system on mobile terminals such as tablets and smartphones. 

Walter AG will be exhibiting its latest developments at the AMB in Stuttgart. Machining experts from across the world will have the chance to see the company’s latest product innovations in the fields of milling, drilling, threading and turning, as well learn about the numerous processes and solutions developed from practical experience.

Thanks to Walter AG’s “Engineering Kompetenz”, customers can be offered innovative products in conjunction with profound process expertise to achieve value-adding solutions for machining. At AMB 2016, the audience of industry professionals will see a demonstration not only of the company’s numerous product innovations but also its expertise when it comes to processes and solutions.

The highlight in terms of products will be the newly developed cutting tool material for milling applications, introduced for the very first time. The company can boast the DC170 Supreme solid carbide drill, the MC232 Perform milling cutter family and a further development in precision cooling amongst its product innovations in the fields of drilling, threading and turning – developments which customers can always count on when it comes to precision, process reliability and cost efficiency.

Of course, Walter AG also takes into consideration the processes that users have to follow. At the AMB 2016, the expert visitors will be shown, amongst other things, how they can link the Walter Multiply service concept with Industry 4.0 service and production in such a way that all processes can become more efficient and, consequently, more economical. As a special highlight this year, Walter will also unveil solutions for the automotive and aerospace sectors. Thanks to a new cutting tool material as well as innovations in machining aluminium and titanium, Walter will once again demonstrate its expertise as a specialist provider of solutions developed through real-world experience.

You can find Walter AG at the AMB 2016 in hall 1, stand G32 The press conference at the AMB 2016 will take place on 12th September 2016 in Walter AG’s new Technology Center at their headquarters in Tübingen.

From 13th to 17th September 2016, Walter AG will be exhibiting its latest developments at the AMB in Stuttgart. Machining experts from across the world will have the chance to see the company’s latest product innovations in the fields of milling, drilling, threading and turning, as well learn about the numerous processes and solutions developed from practical experience.

Thanks to Walter AG’s “Engineering Kompetenz”, customers can be offered innovative products in conjunction with profound process expertise to achieve value-adding solutions for machining. At AMB 2016, the audience of industry professionals will see a demonstration not only of the company’s numerous product innovations but also its expertise when it comes to processes and solutions.

The highlight in terms of products will be the newly developed cutting tool material for milling applications, introduced for the very first time. The company can boast the DC170 Supreme solid carbide drill, the MC232 Perform milling cutter family and a further development in precision cooling amongst its product innovations in the fields of drilling, threading and turning – developments which customers can always count on when it comes to precision, process reliability and cost efficiency.

Of course, Walter AG also takes into consideration the processes that users have to follow. At the AMB 2016, the expert visitors will be shown, amongst other things, how they can link the Walter Multiply service concept with Industry 4.0 service and production in such a way that all processes can become more efficient and, consequently, more economical. As a special highlight this year, Walter will also unveil solutions for the automotive and aerospace sectors. Thanks to a new cutting tool material as well as innovations in machining aluminium and titanium, Walter will once again demonstrate its expertise as a specialist provider of solutions developed through real-world experience.

You can find Walter AG at the AMB 2016 in hall 1, stand G32 The press conference at the AMB 2016 will take place on 12th September 2016 in Walter AG’s new Technology Center at their headquarters in Tübingen.

OPEN MIND Technologies AG is extremely pleased with the response to their presence at the AMB trade fair in Stuttgart. OPEN MIND, a manufacturer of CAM/CAD software and post processors, believes that the high number of visitors at their booth demonstrates that the current development of the hyperMILL® suite has great potential for modern manufacturing.

The reception at the OPEN MIND exhibition booth far surpassed the software maker’s expectations. “We had almost twice as many requests as we did two years ago. The thoroughly positive response to the current version of hyperMILL® shows that we have the right solutions for the needs of the market”, said Claudio Jorio, OPEN MIND’s Sales Director for Germany.

In addition to enhancements of 5axis machining strategies and tool support, two new features in the field of actual CAM functionality garnered a lot of attention. hyperCAD®-S, the CAD portion of the CAM/CAD suite, offers a powerful tool with the ‘Deformation’ module, which provides targeted deformation of geometries. Global and local modification of component areas, which is otherwise usually only possible with elaborate modelling techniques, is particularly interesting for users who want to compensate for the warping of thin-walled parts, such as turbine blades.

Dialogue with the workshop
OPEN MIND presented a highly regarded visualisation solution with the new hyperMILL® ShopViewer. The ShopViewer allows the machine operator to check and simulate manufacturing processes directly via the monitor. The display, analysing and documenting of processed CAD/CAM data in the workshop improves the traceability of the manufacturing process via the toolpath simulation, the material removal simulation and the internal machine simulation. ShopViewer spares you paper documentation and also provides additional security: experienced machine operators can recognise possible errors early on using virtual process analyses.

In addition to the presentations of a newly-developed motor spindle with a cross-feed device and the innovative swivel axis calibration for universal machines, GROB-WERKE will be exhibiting its latest technologies in the fields of energy efficiency and production control systems at the AMB. Der GROB-WERKE trade fair stand is in Hall 5, stand C38.

Since the construction of the new exhibition center, the International Metalworking Trade Fair (AMB) in Stuttgart has been an excellent platform for GROB-WERKE to present its latest developments in the universal machine sector. Six years ago when GROB first demonstrated a universal machine at the AMB, trade fair visitors were able to gain an impression of what it means for the GROB engineers to incorporate and implement concentrated know-how from systems business in the universal machine business. Another example of such a “development” can be seen at the AMB in the newly-developed motor spindle with an integrated cross-feed device for contour turning of complex work pieces. This can be used in the future, for example, to produce the contour of a high-temperature resistant turbocharger housing directly in the GROB universal machine in one clamping operation and therefore much more economically.

GROB will be demonstrating such a process with the universal machine G550 NEW at its trade fair stand C38 in Hall 5. It is equipped with the new motor spindle with an integrated cross-feed device as well as HSK-A100 and a Siemens control unit. It is used at the fair to demonstrate contour turning of a turbocharger made of high-temperature resistant steel and a demonstration work piece made of aluminum. The second GROB machine on display will be the G350 NEW universal machine with the 28,000 motor spindle and Heidenhain control unit. The machine will be processing an aerospace aluminum structural component live in operation with a high cutting rate and tremendous 5-axis dynamics. Finishing is possible with the large swivel range of the axis (225°) in one clamping operation.

Chip-in-spindle detection system (SiS) for universal machines.
GROB will also be demonstrating another technology that can be used for system and universal machine business with its SiS detection system. This system permits peak time neutral detection of tool clamping errors caused by chip inlays between the face of the hollow shank taper and the spindle nose. The special feature of the GROB SiS system is safe and independent detection of very small chips between the tool taper and the spindle taper as well as between the faces of the spindle and the tool holder of 10µm and more. As the detection of tool clamping errors caused by chip inlays is not only a topic in large-scale automotive production, but especially for safety-relevant components, GROB also supplies its motor spindles with chip-in-spindle detection system for its universal machines. This is a system that is integrated into the motor spindle and that inspects the tool interface for possible errors after automatic tool changes. Sensors in the spindle nose detect and evaluate the asymmetric deformation of the tool clamping point caused by chips. Energy and signal communication between the stator and rotor is wireless. The chip-in-spindle detection system is not tied to cycle times and does not require any preparation in the working area of the machine. It is therefore an ideal supplement for enhancing process reliability during automatic tool changes in the machining centers.

New GROB production control system G-Net
The fourth industrial revolution “Industry 4.0” is currently a frequently discussed topic. The “G-Net” Manufacturing Execution System creates cross-work transparency throughout the entire production process by means of web technology. The “G-Net” permits machine feedback for the CIP process and lets the machine “talk” to its environment. Visitors to the fair will be able to see for themselves how G-Net can be used practically by users at the GROB trade fair stand. GROB customers can in future be supported in production with GROB software solutions from CAD models through to the finished component. Customized solutions can be shown with modular applications for topics such as production data acquisition (PDA) and machine data acquisition (MDA) or web-based, mobile reporting. With the G-Net app it is possible to exchange all production-specific data from the ERP und PLM systems directly from the machine. The new G-Net interface permits real-time access to the ERP system from the machine or from the ERP systems to the machine. The perfect interaction between the robust and high-precision G-module range and the intelligent G-Net generates tremendous productivity advantages. GROB has been thoroughly testing G-Net at its own production works for more than a year. G-Net is currently generating more than 60,000 messages per week in the GROB production works – without stress. Machine operators quickly become accustomed to using the intuitive and easy-to-use G-Net user interface with minimal training. The practical findings are directly incorporated into the development cycle. GROB customers therefore benefit from practical solutions for practical applications.

A new dimension of 5-axis accuracy with GROB Swivel Axis Calibration (GSC)
The rotational axes of all machine tools have slight systematic geometric deviations that add up to a total volumetric deviation in the working area. Measuring methods to detect these errors have been developed to cope with this phenomenon. These include the “CYCLE996” and the “CYCLE800” measuring cycles that take the measured values during swiveling into account. With the GROB Swivel Axis Calibration (GSC) GROB engineers have revolutionized this measuring process – another GROB trade fair innovation. With the GSC technology it is possible to almost double the accuracy of the work processes in comparison with existing technologies. This is a tremendous advantage over classic technologies, especially for customers who have to produce very precise parts (individual components), for example in the aviation industry.

This high accuracy is achieved by a more exact description of the kinematics. While conventional methods describe the kinematics with four figures, the GSC typically uses 30. The GSC technology practically replaces the “CYCLE996” or quick-check, as GSC works considerably more accurately and is always active – not only when the “CYCLE800” swivel cycle is programmed. As a result GSC can also be used in automotive applications in which no “CYCLE800” but predetermined zero values are used. In addition measurement is simpler and more flexible. GSC not only enables high-precision work piece machining, but also minimizes the number of necessary run-in parts.

GROB energy efficiency – complex and comprehensive
GROB development engineers have been focusing intensively on the topic of energy efficiency for many years. With their holistic approach they are able to enhance energy efficiency and therefore increase output. The entire complexity of this key issue will be shown at the GROB trade fair stand and an entire range of measures for improving energy efficiency in complex production systems and universal machining centers will be explained. GROB specialists will be explaining the effects on energy efficiency when a system can look into the future with the MES (Manufacturing Execution System) and knows exactly which job is coming next and when the system can “sleep” because there is nothing to do or when it has to “wake up” so that it can prepare “just-in-time” for production of the next part. There is hardly a field of research that is so complex and comprehensive, as it has to deal with the technology, i.e. the product, the optimum production of the components and also the entire manufacturing strategy.

At AMB 2014, Sandvik Coromant, the global leading supplier of cutting tools, tooling solutions and know-how to the metalworking industry, will introduce visitors to a variety of technologies and services for optimized machining across a range of processes and industries. In line with the theme of ‘get extra power for your success’, improved performance and efficiency will be the focus of the company’s 368 square meter ‘Smart Hub’ (Hall 1, booth E52) at this year’s exhibition.

Technologies and expertise at the ×Stuttgart event will encompass the entire chip removal process and emphasize ×Sandvik Coromant market leadership in the precision tools industry. As well as innovative turning and gear milling tools for manufacturing advanced components ×Sandvik Coromant will present solutions to the latest challenges in the automotive or aerospace industries. The Sandvik Coromant trade fair team, consisting of a staff of 40 experts, will be on hand to demonstrate the comprehensive portfolio of services that increases efficiency, profitability and know-how.

Throughout the show ×Sandvik Coromant will also present “Machine Investment” concepts that help customers to gain significant competitive advantage – for example through the definition and analysis of both the technical and economic aspects of new investments.

‘At this year’s AMB, we will show that with our technologies and services we can optimize any machining process and make it more economical – no matter if its turning, hard part machining or gear milling, to mention just a few examples,’ says Dr. Klaus Christoffel, manager marketing and product management at ×Sandvik Coromant in Germany.

With its service team, ×Sandvik Coromant will also again offer comprehensive services relating to machine equipment before and during AMB. The service team can be found in Hall 5, Room 5.4 from one week before the start of the trade fair.

The German machine tool giant EMAG is all set to showcase its revolutionary PMD 2 Grinding Machine at the upcoming exhibition AMB 2014. EMAG will present the PMD 2 for the first time at the international metalworking exhibition, the AMB, in Stuttgart. This machine from EMAG NAXOS-UNION provides for high output rates and impresses with its excellent price-performance ratio. The premier exhibition will be held from 16 – 20, September, 2014 in one of the biggest industrial hub Stuttgart.

International competition in the automotive industry is increasing apace. According to the latest studies so are the technological demands on vehicles – and with them the costs. But increasing prices in the face of stiff competition in the market is no longer easily defensible. In production terms, the costs incurred in the manufacture of passenger cars need to be reduced by three to four percent per year to retain current profitability levels – according to a McKinsey study. And this is a staggering percentage.  But what does it mean when it comes to manufacturing technologies? The example of the crankshaft clarifies the point. Here, a lot depends on the grinding process carried out on this core engine component. In future, the process needs to be of greater precision and subject to an even higher degree of efficiency. The grinding experts at EMAG offer an interesting alternative in their PMD 2 Crankshaft Grinder.

Actually, the prospects for the automotive industry internationally are very good. The next few years are expected to see noticeable growth (especially in the Asian growth markets). But it is also true that the competition is, in many respects, becoming more complex.  In Asia, for instance, new competitors are crowding onto the market. In addition to that, more rigorous national emission limits and safety requirements are leading to an increase in production costs. As a consequence, the eye of the planner is on the manufacturing technology. How can the cost increases be reversed? Crankshaft machining is again a good example. The efficiency and stability of the engine depends on this core component. The grinding process therefore includes a (work-intensive) fine-machining operation in the micrometre range. And this has always been a job for the expert – also where the manufacturer of the relevant technology is concerned.

New capital investment
The machine builders at EMAG have, for decades, relied on a high degree of knowhow in this sector. Among other machine tools, the company – with  headquarters in Salach, near Göppingen, Germany – also develops tailor-made grinding solutions for shaft-type components. The new machine PMD 2 complements their crankshaft grinder program. It is designed for the machining of crankshafts for passenger cars and features twin grinding heads that allow for the simultaneous grinding of two pin or main bearings in a single setup, using two grinding wheels. Its capacity covers small components of up to 500 mm length. “With this machine we are rounding off our range of crankshaft grinders to include the machining of smaller components,“ explains Dr Guido Hegener, Managing Director of EMAG Maschinenfabrik GmbH. “Up to now, our range of machines did not include a horizontal twin-head grinder for smaller crankshafts. This gap is now filled with the PMD 2, a machine the excellent price-performance ratio of which is also ideally suited to combat the increasing competition in the automotive industry.“

Outstanding precision guaranteed
The developers at EMAG have been able to fall back on tried and tested technologies. The basis for the PMD 2 is the well proven „Series 2“ of EMAG NAXOS-UNION and EMAG KOPP. These machines combine high-tech grinding technology with precision, great efficiency, process integrity and simple operation. That applies to the PMD 2 as well, of course, where two CBN grinding wheels machine crankshafts to the highest precision. To achieve this, the machine is equipped with a direct-driven workspindle, hydrostatic guideways and a linear motor in the X-axis, as well as an in-process measuring control that allows for roundness monitoring and correction in the machine. “The operator enters the relevant command in the control and the measuring process is carried out once the bearing has been ground. The software, developed by EMAG, then calculates the relevant correction values from the remaining roundness errors. This allows for the subsequent manufacturing processes to be successively optimised“, adds Mr Hegener.

Shorter cycle times – increased productivity levels
The technology also scores with its simultaneous use of two grinding wheels. The twin-tool process opens up a number of possibilities for the user, depending, of course, on component and machining requirements. Two pin bearings or main and pin bearing are machined simultaneously, leading to a reduction in cycle times. For instance, a four-cylinder crankshaft is machined in less than two minutes.  The grinding wheels can, if required, be arranged very close together, so that adjoining pin and main bearings can be machined simultaneously. Both, grinding spindles and work headstock are direct-driven. This further increases precision and productivity levels. “We have strung together a technologically very interesting package“, concludes Herr Hegener.

Flexible Configuration
The machine is also of compact but flexible construction. The enclosure includes, for instance, the electrical cabinet. Connecting up an automatic loading system is also no problem. And both, emulsion and oil can be used as coolants. “Flexibility was for us of great importance in using this technology“, confirms Herr Hegener. “We tailor the machine exactly to the customer’s requirements. Integration of the machine into an existing, complex production line is an important option. But we can also see the machine being used as a stand-alone solution, with manual loading“.

EMAG will present the PMD 2 for the first time at the international metalworking exhibition, the AMB, in Stuttgart. The international character of this trade show perfectly suits the strategy of the machine builder from Salach, as the machine can be used in a multitude of markets and production environments. “We are expecting great things from this flexible, efficient approach,“ explains Herr Hegener in conclusion. “The PMD 2 will give both Asian and European users a competitive edge. Component quality and production costs are gaining in importance everywhere. We are looking forward to showing our visitors at the AMB the quality of this technology.“

For more details contact EMAG Holding Gmbh