Technology trends in machine tools

But it seems we are nearing the limits of what is technically feasible. In view of the high technical sophistication of the machines, according to Prokop the challenge lies in the expansion of the service offer with an enhanced customer benefit.

Further potential through networking

The path to achieve this seems to be sketched out with the buzzword "Industry 4.0", created in 2011 by the German government. "It is about generating new customer benefits through networking. Many activities can be simplified or even automated, also in our private lives", explains Prokop. However, thinking in networking solutions is still relatively new for many companies and requires a different angle. The focus can no longer be on the machine alone. Rather it must be optimally embedded in the intralogistics of a company.

One or two exhibitors of the key sector characterised by medium-sized companies are somewhat uncomfortable or nervous about these prospects. Are the nerds now taking over the machine control? Is there a threat of similar developments like in the automotive industry where the giants of the digital world want a sizeable piece of the pie as lateral entrants?

Don't panic!

Professor Dr.-Ing. Gisela Lanza is head of the production systems division at the wbk Institute of Production Technology at the Karlsruhe Institute of Technology (KIT). Global production strategies, production system planning and quality assurance are her topics. Her advice is to get involved in the topic intensively, without giving in to a state of panic. "The smaller and medium-sized companies should address the topic in small projects. They can benefit greatly from their speed and agility in this topic, but must use their resources and capacities in a purposeful manner."

The increasing significance of the topic is also confirmed by Jochen Nahl, Member of the Board of Management of Grob-Werke GmbH & Co. KG (Hall 5, Stand C38): "Generally speaking the AMB visitors are expecting flexible production systems, which offer the possibility of networking with other machines and systems." Analysis data and databases also become relevant, "in order to achieve higher availability and efficiency with production systems."

The Austrian Emco Group (Hall 5, Stand B75) sees the topic in a more sober light. CEO Dr. Stefan Hansch: "Aside from all visions and unrealistic expectations of the Industry 4.0 hype, the customer benefit alone is what counts in practice. For the operator it is always about having the right information available at the right time in the right place."

Machines are becoming more powerful

Notwithstanding all the bits and bytes, the machine tools themselves are becoming more and more powerful and efficient. Dr.-Ing. Oliver Gossel, Marketing Manager, Röders GmbH (Hall 9, Stand C58), describes an example. The latest technology achieves "considerable savings in the machining time through optimisation of control and path planning". And the production of optical surfaces is now even possible in hardened steel. Accuracies of +/-1 μm on the workpiece or surface qualities of Ra 5 nm in hardened tool steel can be achieved today.

Walter Börsch, CEO of the Swiss Starrag Group (Hall 7, Stand C38) with several subsidiaries in Germany, is also expecting more than pure software innovations from AMB. "Technology trends include kinematics, which enable complete machining, machines with higher productivity per footprint and machine configurations adapted to the respective customer benefit."

Integration of new technologies

Another hot AMB topic: "Additive manufacturing". This relatively new production process is not likely to pose a direct threat to machining during the transition to series production. But the machine tool manufacturers cannot avoid it completely, the advantages are too remarkable. Hence why they are simply integrating such processes in their machines, is how Manfred Maier, COO, Heller Group (Hall 5, Stand B55), describes it. It is about "the intelligent combination of material application, composite and removal. Laser technology, friction stir welding, metal injection moulding and other technologies come into play here." Heller is already using this process successfully for the coating of cylinder bores in aluminium crankcases of combustion engines.

The programming and printing in 3-axis machining centres is already also a reality at Hurco GmbH (Hall 5, Stand C72). "At AMB we are showcasing a machining centre with a 3D print head", announces President Michael Auer. The head sits in a tool-holding fixture like a traditional tool. "3D models can thus be programmed and printed in 3D for the first time in a single process and without any interruptions; machines, materials and costs are used efficiently and in a resource-friendly manner."

Efficient machining at one setting

Danny Basic from SHW Werkzeugmaschinen (Hall 9, Stand C52) GmbH examines a full range of technology trends beyond the soft goods: "In the complete machining of increasingly complex large components machining at one or as few as possible settings, as well as increasing requirements regarding efficiency in production, are still in demand." For the users it is about "machining times, energy costs, tooling times, low-manpower production and multiple machine operation".

The motto is thus not only metal forming. "In general the trend continues towards the integration of several technologies in one machining operation, intensive and reliable automation", states Udo Hipp from the machine plant Berthold Hermle AG (Hall 7, Stand D52).

"Modularity and diverse applications are a strong selling point for the user of machine tools", also reports Stephanie Riegel-Stolzer, Member of the Board of Management of Kasto Maschinenbau GmbH & Co. KG (Hall 6,

Stand B11/12). The trend is moving away from expensive custom-built designs, and towards cost-effective and economical standard solutions, which "can still complete many different tasks".