Product category:
Manufacturing exhibitions
News Release from: VDW | Subject: METAV manufacturing technology show report
Edited by the Manufacturingtalk Editorial
Team on 19 July 2006
METAV focused on systems integration,
optimisation
Manufacturing technology exhibition, METAV Dusseldorf 2006, focused on machining systems integration and automation, as well as optimising machine performance, reports Reinhard Guserle.
METAV Dusseldorf 2006, the International Trade Fair for Manufacturing Technology and Automation, presents numerous innovations and new developments in the areas of machine tools, precision tools, accessories and services System integration and automation in manufacturing remain central themes
This article was originally published on Manufacturingtalk on 12 Sep 2005 at 8.00am (UK)
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New technological trends were not only observed in the machine concept and precision tool fields but also increasingly in detail solutions that contribute to optimising machine characteristics and manufacturing processes.
Aspects such as improved accuracy in system integration, precision machining and cost efficiency were focal points, as were new applications such as miniature pump manufacture for medical device technology.
With the lecture event 'praxis+trends', METAV Dusseldorf 2006 offered a discussion platform for developers and scientists on the topic 'Simulation - An Investment in the Future' for the first time.
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* Innovation in detail - innovation in detail was an especially strong characteristic of METAV Dusseldorf 2006.
A multitude of solutions for manufacturing and automation were presented.
Driven by the goal of improving accuracy and increasing machine dynamics in primary and secondary shifts while continuing to cut costs, manufacturers presented their solutions for a wide variety of applications.
'Innovation in detail' was reflected for example in innovative bearings for direct drives or ready-to-mount spring-loaded spindle bearing units for complete production machine systems.
Due to their high level of precision, these optimised bearing systems achieve improved load bearing capacity.
The products are attuned to each other for their system application and to the customer's systems.
Important functions such as measuring, sealing, lubrication or braking are integrated, leading to fewer interfaces and higher accuracy.
Other advantages include smaller footprints, easier mounting and a higher number of maintenance-free parts.
Characteristics that can lead to an increase in spindle revolutions or longer life cycles.
The mount-ready spindle bearing units are extremely compact, allowing machine tool manufacturers to quickly, reliably and efficiently integrate them into their systems.
Machines become more compact, perform better and are more economical.
(Example: Schaeffler, Herzogenaurach, Germany) * Cost reduction through robot deployment - cost reduction in systems may be realised by the use of flexible robotic cells.
The deployed robots allow rapid assembly of complex component groups by way of attuned loading as well as machining operations, which are supplemented by assembly and test procedures.
(Example: Haindling-Tech Automations-Systeme, Stuttgart/Moehringen, Germany) Additional cost-reduction potential is offered by automation concepts using special pallet-changing and extra tool magazines for single-piece or short-run production (example: Hermle, Gosheim, Germany www.hermle.de).
* High-precision machining through precision tools - at METAV one company showed an improved hydrostatic tool for surface bonding when roller burnishing and deep rolling complex, thin-walled components.
In collaboration with the machine tool laboratory (WZL) of the RWTH in Aachen, Germany, the designer managed to offset the burnishing forces by a tongue-like tool design.
Based on the principle of hydrostatic tools, it is equipped with two roller elements that feature a rotary degree of freedom that keeps the material out of exigency, making it possible to 'tailor-roll' the blanks.
The use of this tool increases surface quality and hardness while reducing inherent stress when roller burnishing and deep rolling.
These three factors have a decisive influence on the life cycle of parts under dynamic stress (example: Ecoroll, Celle, Germany www.ecoroll.de).
The improved life cycle has led to increased use of burnishing and press polishing, for example in sports car and commercial vehicle manufacture as well as in the aerospace industry.
In the tools segment, the latest coating developments for increased tool life were presented, which also lead to improved machining and performance capabilities with entire machine tool systems.
In practice this means that the AlCrN-based coating 'Balinit Helica' allows more holes to be drilled while reducing drilling process times.
The multi-layer texture, applied by means of the PVD coating method (physical vapour deposition), ensures high shear strength and homogeneous wear and is characterised by high tear-strength and toughness.
The exceptionally smooth surface facilitates excellent chipping discharge.
'Balinit Helica' coating features a much better wear resistance than common titanium aluminium nitride coatings, allowing the automobile industry to manufacture transmissions in a cost-effective manner (example: Balzers Verschleissschutz, Bingen, Germany, www.balzers.de).
* Chucking systems for every application - each specific application places unique demands on a tool holding system.
Solutions for a variety of processes were presented, intended to ensure the highest possible holding strength.
A tool holding system was developed for HSC (high speed cutting) milling, for example, that guarantees highly accurate machining at spindle speeds as high as 60,000 rev/min.
Especially impressive: the compact form, holding diameter (starting at 0.3mm) and the optimum vibration damping.
Chuck systems for minimum volume lubrication were also presented (example: Schunk, Lauffen/Neckar, Germany, www.schunk.de).
* High-performance spindle systems - next to tools and tool holding systems, high-performance drive spindles allow precise machining.
A new high-frequency spindle shows that the HSK25 tool holder can be used even at the high speed of 75,000 rev/min.
Such high-frequency spindles make a decisive contribution to high-precision processing with smaller tools in mould and die making or high-performance grinding (example: GMN Paul Muller Industrie, Nuernberg (Nuremberg), Germany).
The wide variety of spindle systems presented at METAV Dusseldorf 2006 show how important it is to make the right selection for each application.
This choice often makes the difference between success and failure in the machining process.
Each application whether mould and die making, mass production or the aerospace industry places unique demands on motor spindles.
The goal is always to achieve a dynamic yet extremely stiff construction with high performance density, which equates to machining volume for customer use.
Here as well, innovation in detail is necessary.
The bearing units must harmonise with the hybrid bearings based on the utilised material for the balls or for outer and inner rings in combination with the lubrication or outer ring direct lubrication.
Only in this manner can maximum speeds be attained with large, stiff bearings (example: Step-Tec, Luterbach, Switzerland, www.step-tec.com).
* Precise positioning - the extreme weight of spindle and tool holding systems including tools must be precisely and quickly positioned.
A 600kg milling head, for example, is accelerated by way of a direct drive, then braked, during which up to six times its nominal torque must be controlled.
Additional applications such as brakes ensure maximum operating safety for the system.
By guiding the milling head with a recirculating ball screw and integrating the lag nut into the motor, a high level of static and dynamic stiffness between spindle and motor can be achieved, leading to increases in acceleration capability, positioning accuracy, uniformity and life cycle (example: Servax Landert Motoren, Buelach, Switzerland, www.servax.com).
* Increasing performance and precision - translating innovations directly into increased productivity and improved precision, flexibility and dependability goals that machine tool manufacturers and their customers alike strive for.
In order to achieve these goals, the following technical details must be kept in mind during development: increased productivity is achieved through high torque and high spindle performance in combination with higher speeds and spindle revolutions.
Increasing the stiffness, for example of the feed drives, can be realised through a pre-tensioned high-precision recirculating ball screw with a power nut.
The longitudinal extension must be automatically compensated.
Central and symmetrical positioning of the headstock in the machine stand has proven to be best for thermal stability.
Spindle bearings can be lubricated by way of minimum volume lubrication.
Flexibility is achieved through various automation scales, both for mass and for single-piece production.
The reliability of such a machine can be increased through simple maintenance programmes and user-friendliness.
A remote monitoring system facilitates effective troubleshooting (Example: Pama, Rovereto, Italy, www.pama.it).
The achievement of the listed goals was presented at METAV Dusseldorf 2006.
* Proven machine concept for highest dynamics - drive dynamisation continues to dominate machine tool development with the goal of increased productivity.
Equipping gantry milling machines with linear drives is proof of this.
HSC milling with small tool diameters can be achieved through high feed rates of up to 60m/min and a high spindle speed of 35,000 rev/min, allowing chip removal volumes of up to 6000cm3/min with aluminium.
The use of torque motors for rotary worktables and swivel axis enables the realisation of a high dynamic for rotation axes.
In order to achieve high acceleration values in the rotation and translation axes, you must have an adequately stiffened frame construction, which can be realised through a grey cast iron bed, welded sidewalls and a welded gantry and Z-slide.
Vibration damping and thermal stability is achieved by caulking the frame components with reaction-resin concrete.
The thermal inertia and damping characteristics of reaction-resin concrete have a positive influence on the thermal and inherent vibration behaviour of the machines (example: F Zimmermann, Denkendorf, Germany, www.f-zimmermann.com).
* New applications for manufacturing technology - with the appropriate machines and tools, machine manufacturers can break into new markets above and beyond classic applications of manufacturing technology.
Medical device technology offers a good example of this.
In addition to dental implants, pins for bone fractures and hip joints, there are now numerous new products that can be manufactured on machine tools.
The surface of a ceramic hip joint is smoothed and its shape perfectly adapted to the human anatomy using a diamond tool.
High-quality titanium nails, connecting pins and parts for miniature pumps used in heart surgery also belong to the range of products.
In addition, tools and special components for packaging machines for medical device technology (e g, for ampoule fabrication) are manufactured.
Further applications include laser welding of heart pump cases and laser inscription, which also facilitates product labelling.
The aerospace industry is an additional application field.
Here, the special challenge lies in mastering large components.
Complete micron-accurate processing opens the door to new perspectives for manufacturing technology.
Regarding processes, new methods come into play such as combined ultrasonic and milling or laser and milling.
Ultrasonic technology allows precise rod lens production of glass and corundum.
High-frequency excitation results in an active vibration of the tool, which in turn makes the diamond cutter pulsate vertically up to 48,000 times/s depending upon the type of spindle used.
This ultrasonic excitation allows the removal of miniscule particles from hard, brittle materials up to five times more quickly than by conventional methods.
Precise tooling of hard-to-machine materials using diamond tools is similar to a facing operation and ensures high surface quality (example: Firma Gildemeister (DMG), Bielefeld, Germany, www.gildemeister.com).
* Lecture series praxis+trends at METAV Dusseldorf 2006 - 'Manufactured as planned! The potential of simulating machine tools, processes and production' - "Germany has the advantage through know-how and high-tech applications," according to a headline in the preliminary reports on METAV Dusseldorf.
Innovative ideas that translate quickly into real-life products and processes are the success factors for increasing competitive ability.
The simulation of product characteristics and their manufacturing processes in the early development stages gains importance continually and is becoming a guarantor for technological leadership and reaction speed on the global market.
In the words of Rainer Mueller, vice president, Research and Development at Siemens Automation and Drives in Erlangen, Germany, "He who started early is ahead today." For the first time, experts from machine tool manufacturing companies, systems providers and scientists lectured on the topic 'Manufactured as planned! The potential of simulating machine tools, processes and production' in the framework of the METAV event 'praxis+trends'.
The central theme was the use of simulation techniques for machines and processes in development as well as the practical application within the companies.
The potential for companies as well as the limitations of various simulation methods were demonstrated in the context of the daily routine within the machine tool industry.
The efficiency of simulation technology for engineering mechanics was demonstrated using design optimisation of a structural component as an example.
In addition, industry representatives showed how simulation on the factory level can allow a higher level of system productivity by the use of virtual tools.
In the area of multi-disciplinary simulation, the simulation of a machine tool's entire life cycle was shown using the example of a systems provider.
The goal here is to maintain and continually improve the level of product quality, machine reliability and productivity.
From the research point of view, impulses for future development and simulation were presented.
Integrated, coupled simulations of machines, work-pieces and processes, as well as the still unsolved problems, were illustrated and discussed on the basis of various models.
The efficiency of applied simulation methods were demonstrated using exemplary comparisons of measured and simulated machining forces.
Further, uncertainties and the possible development potential of integrated, coupled simulations were illuminated.
In addition, participants were tutored in the subject by way of forecasts on stability limitations in milling as well as the influence on model structure and parametrisation.
The event concluded with a presentation of a virtual-reality based development platform for machine tools (VRAx) and its potential for the four abstraction levels of simulation technology (factory, system, machine and process).
* Summary - METAV Dusseldorf 2006 impressed with innovative solutions for manufacturing and automation technology.
Exhibitors were able to present systems to customers and interested parties in detail that allow them to structure their manufacturing processes more rationally, efficiently and accurately.
METAV Dusseldorf 2006 was an extraordinary show of performance for the national and international machine manufacturing industry.
Around 47,500 visitors contributed significantly to the success of the trade fair for manufacturing technology and automation for the exhibitors.
With 'innovation in detail', new machine concepts, high-performance precision tools and intelligent auxiliary devices, but also with more customer-oriented service, machine manufacturers were able to offer increased productivity and pique the interest of their customers.
Through the increased demand for high-end products offering maximum accuracy and process command, the economic upswing was successfully perpetuated at METAV Dusseldorf 2006.
* About the author - Reinhard Guserle is a qualified physicist at the IWB Institut fur Werkzeugmaschinen und Betriebswissenschaften (Institute for machine tools and business sciences), TU Muenchen (Munich), Germany.
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