These include high-speed, multi-sensor measurement systems for CMMs; high-accuracy and high-speed products for machine tool probing; flexible shopfloor gauging systems; new calibration and encoder innovations for machine builders; and new additive manufacturing solutions.
The ‘Metrology and Quality Assurance zone’, located within hall 6, will be home to Renishaw’s largest stand (stand D48). Here, visitors will be able to see Renishaw’s Revo 5-axis measurement system in action and discover how it delivers high performance multi-dimensional inspection, including surface finish analysis.
To showcase the Revo system’s latest blade measurement capabilities, there will be a demonstration of an aerospace component being inspected on a coordinate measuring machine (CMM). Visitors will discover how the Revo system automates the part inspection process on a single, multi-sensor platform, and will learn how it is being used across industries where the highly accurate, but rapid, measurement of different forms and features are essential requirements.
Visitors will also be able to see Renishaw’s modular and custom metrology fixturing, as well as a demonstration of its first automated direct loader transfer system for use with CMMs, which complements the benefits of automation and rapid throughput that the Revo system brings.
Renishaw’s new Optimum diamond styli range will be showcased, which has been specifically developed for use within metrology applications that require a hardwearing stylus. Additionally, Renishaw’s latest Sprint technology will be on display – high-accuracy machine tool probing systems for rapid part set-up and machining process control.
Staying with probing, Renishaw will demonstrate its range of high-accuracy machine tool probes with Rengage technology for workpiece set-up, in-process control and post-process inspection. The latest addition to Renishaw’s range of machine tool probes with the technology is RMP400 – a new, ultra-compact and highly repeatable probe that uses radio transmission technology.
Elsewhere, building on the success of its enhanced NC4 range of tool setters launched at EMO 2017, Renishaw will launch the NC4+ Blue – its latest evolution of the non-contact tool setter, delivering a step-change in tool measurement accuracy.
Compared to red laser sources found in conventional non-contact tool setters, blue laser technology (patent pending) has a shorter wavelength, resulting in improved diffraction effects and optimised laser beam geometry. This enables the measurement of very small tools, whilst minimising tool-to-tool measurement errors – a critical consideration when machining with a wide range of cutting tools.
Renishaw's Equator shop-floor gauging systems are being used to great effect around the world to measure a vast array of manufactured parts, particularly in the aerospace and automotive industries. They enable intelligent process control of manufacturing cells and lines by delivering highly repeatable, thermally insensitive, versatile and reprogrammable shop-floor gauging.
There will be demonstrations of Renishaw’s machine calibration and diagnostic technologies, designed to monitor the static and dynamic performance of machine tools, CMMs and other position-critical motion systems, to ultimately establish a known and repeatable level of process capability.
These will include Renishaw’s new XK10 alignment laser system which has been developed to measure geometric and rotational errors of machine tools. Used with the XK10 machine tool fixturing kit, it enables faster and easier measurements over traditional methods, such as dial gauges, autocollimators and metrology artefacts.
XK10 can be used on linear rails to ensure that they are straight, square, flat, parallel and level, as well as to assess spindle direction and coaxiality of rotary machines. Live error readings allow adjustments to be made to the machine during the alignment process. A range of Renishaw’s high quality optical, magnetic and laser encoders will also be on display. This will include its new substrate mastered RKLC encoder scale that adopts the thermal behaviour of the underlying substrate.
On its stand in hall 6 (stand D48) Renishaw will introduce its first ever ‘Solutions Bar’. Visitors will be able to ask Renishaw’s team of experts about a variety of process control, metrology products or manufacturing queries, whilst enjoying much-needed refreshments.
In Hall 3 (stand E36) within the ‘Precision Tools’ zone, Renishaw will focus on smart manufacturing technologies for the metalcutting sector. Using its machining demonstration cell with automated part loading, on-machine probing and off-machine gauging, the company will demonstrate how automation, measurement and feedback can deliver process control throughout all manufacturing stages.
Visitors will also discover Renishaw’s full range of on-machine and smartphone apps which make installing, configuring, using and maintaining probing systems even easier, saving time and maximising shopfloor efficiency through enhanced automation.
Extending Renishaw’s smart manufacturing technologies further up the process chain, Renishaw’s stand in Hall 9 (stand I23) within the ‘Additive Manufacturing’ zone, will showcase its latest additive manufacturing (AM) systems and solutions.
This will include a live demonstration of the RenAM 500Q – its high productivity multi-laser system – building metal components. Featuring four high-power 500W lasers, each able to access the whole powder bed surface simultaneously, the RenAM 500Q achieves high build rates and component quality vastly improving productivity and lowering cost per part.
Hall 3, Stand E36
Hall 6, Stand D48
Hall 9, Stand I23
Starrag’s success policy across all its product lines - Berthiez, Bumotec, Dörries, Droop+Rein, Ecospeed, Heckert, Scharmann, SIP, Starrag and TTL – in companies of every size and across all industry sectors, has been built on providing machining solutions tailored for individual customer needs.
That extends from a standalone machine with, for example, bespoke workholding and tooling solutions as well as certain spindle and machining head options such as those required for single set-up multi-tasking machining that may involve milling, boring, turning and grinding. And it extends through to fully automated flexible manufacturing systems with multiple machines complemented by sophisticated workpiece handling/transport options.
Whatever the size and scope of machining, Starrag can also supply the appropriate cell and software control necessary for 21st century manufacturing, whilst simultaneously embracing a host of functionalities for the integration of Industry 4.0 strategies, too.
Examples of all these technologies will be available on the EMO stand which will feature a small sample of the extensive range of machines available from the Starrag Group. On show will be: a Starrag NB 151 blisk and impeller machine; a Heckert T45 5-axis horizontal machining centre with rotary table; a Bumotec s181 5-axis mill-turn centre; and a Sprint Z3 parallel kinematic machining head.
Targeted at blisks and impellers up to 600mm in diameter, Starrag’s all-new NB 151 features a number of developments for the effective and efficient machining of blisks. In particular, an innovative rotary (A and B) axes spindle allows the tool/cutting angle to be positioned relatively close to the workpiece, resulting in not only a more stable machining process but also an effective route to minimal cycle times.
With X, Y and Z axes travels of 700mm x 750mm x 750mm, respectively and rapid traverse rates of an impressive 80m/minute, the T45 is one of a range of Heckert T series 5-axis horizontal machining centres.
Crucially, with a fast-rotating (900rpm) trunnion table, the machine is ideal for the complete production – including turning routines - of complex workpieces in a single clamping position.
From Starrag’s Bumotec range, the s181 5-axis turn-mill machining centre will be demonstrated machining a titanium steel spine surgical hook from 25mm diameter bar – applying a total of 17 tools (including five live tools) to complete the part in under 14 minutes compared to almost 20 minutes on a single-station machine.
The machine – which has a 30,000rpm HSK 40 spindle (optionally 40,000rpm) and 90-tool magazine – will also feature ESPI’s Scanflash technology for inline production monitoring/transfer of correction values directly to the machine to, if necessary, automatically make instant adjustments to production parameters.
Also on show, the Sprint Z3 parallel kinematic machining head is an invaluable aid to improved machine performance and flexibility. The head uses three parallel linear axes drives mounted radially equi-spaced in the headstock. The spindle platform is connected to each drive via rigid levers with pivots at each end and a ball joint at the other.
When all three axes move simultaneously, the spindle is moved in a straight line in Z; synchronised motion of the three Z-axes allows the spindle to follow any path within a spherical cone of ±40° at a maximum of 80°/second. If the three axes move differentially, the spindle platform will be tilted in the A/B kinematic.
Hall 12, Stand B58
Nearly all automobile manufacturers have started manufacturing electric vehicles in series production and are using large-format structural parts made of light metals to further reduce weight.
"The single-spindle BA W08-12 is specially designed for machining large parts," explains Reiner Fries, managing director of sales at SW. "Like the other SW linear motor machines, it achieves higher dynamics than most competitor machines and thereby boosts productivity directly." The BA W08-12 provides a working area of 1,500 x 900 x 650mm for 4- and 5-axis machining.
Two-spindle machining centres double the output with a smaller footprint than using two machines and less energy consumption. In the fully automated, independent BA 322i manufacturing cell, the loading module with integrated 6-axis robot and pallet storage is already mounted on the machine.
"The storage is adequate for complete unsupervised shifts, but it can be replenished at any time without stopping the machine," Mr Fries explains. “With a spindle distance of 300mm, the working area is 300 x 450 x 375mm. Automotive suppliers or users in medical technology and precision mechanics are following this approach to significantly lower the unit costs of production.”
SW’s algorithms are the result of experience gained from millions of operating hours
"We have been networking our customer machines for many years and have created the SW CloudPlatform from the ground up with very high security standards,” Mr Fries reveals.
“I wish more users would set their fears aside and use the data so they can achieve and preserve maximum productivity for the entire machine lifecycle. As one of the six modules of the ‘life’ services portfolio, we record operating data for the customer with ‘life data’ as well as status and maintenance information.
“The encrypted data is also sent only where the customer wants to receive it. With condition monitoring functions we also enable predictive maintenance, which saves time and money."
In some cases customers are able to carry out upgrades themselves or alternatively with the support of SW staff. All SW life services modules are integrated with each other to ensure optimum support of SW machines over their entire lifecycle, offering potential for maximum optimisation.
Hall 12, Stand C58
For example, visitors will be able to learn about a new laser marking and cleaning station for the Walter Helicheck Plus tool measurement machine.
In addition, included among the myriad of Group machines on show, Walter will be showcasing tool grinding/erosion, and measurement, machines while Ewag will focus on insert production centres and laser-based tool manufacturing.
Helitronic Power 400 with top loader: a 24kW spindle machine for the production and regrinding of tools of 3mm to 320mm diameter and up to 350mm long. Integrated into the machines’ existing construction and with no restriction to the working envelope, the top loader has a pneumatic swivel arm with gripper to integrate with Walter’s standard robot pallet system for tools up to 32 mm diameter. The two-pallet system, one each for blanks and finished tools, can each accommodate up to 500 tools (depending on size).
Helitronic Power Diamond 400 with robot loader: a single machine that can both erode PCD tools and grind carbide tooling, even in the same set-up (a tool’s carbide body and its brazed-on PCD tip) with tools from 3mm to 380mm diameter and 520mm long. The robot loader can accommodate 21 tools of up to 315mm diameter and weighing 25kg (or 28 tools of up to 220mm diameter; 70 tools up to 105mm diameter.
Helicheck Plus tool measurement machine with robot loader: the robot loader brings effective automation to the unmanned measurement of complex tooling. Depending on tool weight and length, up to 2,000 tools with a maximum weight of 1.5kg and a maximum length of 280mm can be automatically loaded.
Each tool is measured, recorded and separated on pallets (four standard; optionally eight). During the process, tools can also be cleaned before measuring as well as laser-marked in the Robot Loader cell.
Laser Line Ultra: for the ultra-short pulse laser machining of all cutting materials, including CBN, ceramic, PCD and CVD, accommodating inserts up to 200mm diameter and up to 250mm long. The machine features an integrated 6-axis robot.
Profile Line: for the production of complex insert geometries, including interchangeable cutting inserts and rotationally symmetrical drilling and milling inserts of HSS, carbide, cermet and ceramic. This also has an integrated 6-axis robot for autonomous operation.
Hall 11, Stand B24
The introduction of the Vusp and Vupo taps embeds the experience and threading expertise gained over decades to provide the industry with a state-of-the-art product.
Vusp (spiral fluted taps for blind holes) and Vupo (spiral pointed taps for through holes) are designed to deliver top performances both in mass production and small batches applications, without jeopardising performance, reliability and quality.
“In the current production scenario, flexibility is the key that helps our clients deal with different requests quickly while ensuring the utmost quality,” says Alessandro Sorgato, CEO of Yamawa Europe. “Our new taps – part of the Z-Pro range – are designed to be used in modern multi-function machining centres, allow our clients to obtain the highest performance on different materials, such as steel, carbon steel, alloy steel, stainless steel and aluminium.”
Both variants have been developed to provide continuous and reliable tapping, as well significantly extend tool life through excellent chip evacuation. The new taps feature an innovative flute design allowing optimal chip control and lower cutting forces resulting in excellent finish quality in internal threads.
The taps are manufactured from premium quality powder high-speed steel, to Yamawa’s specifications and featuring a new special coating to maximise wear resistance.
The Z-Pro line enhances an extensive portfolio of taps and threading tools recognised by the industry for quality and depth of the functionality. Yamawa has a production capacity of 1,600,000 tools per month across four plants in Japan. Every tap that leaves the factory undergoes a triple quality check.
As a technical innovator, Yamawa is aiming at developing projects and structures enabling European end-users to get easier and faster access to its expertise. In the past few weeks, the Japanese company has inaugurated the Yamawa Academy in Mestre (Venice, Italy).
“The Academy is a fully-equipped space that allows us to train our clients from both a theoretical and practical point of view,” Mr Sorgato explains. “Besides the new high-tech training room, which can accommodate up to 40 people, we have added a new workshop equipped to perform practical exercises and tapping tests.
“This area will allow our customers to verify operational parameters such as the impact on thread quality and chip control when considering varying factors such as cutting geometry, diameter variation of the bored hole, cutting speed variation and the different material behavioural characteristics”
Yamawa will provide a consultation service for tapping-related problems and challenges at every trade fair it will be attending: “The company has already implemented this idea at the latest Jimtof trade fair in Tokyo, where it proved to be a success.
“In Europe, we started in June at the ITM trade fair in Poznan, and now we are ready for EMO. Throughout the event, one of our technicians will be available at the ‘Ask the experts’ area within Yamawa’s stand in Hannover to help anyone who has problems or questions related to a particular tapping application.” Mr Sorgato affirms.
Yamawa Europe’s challenges don’t stop here. The company is also developing a series of projects focusing on those who will be leading the metalcutting industry in the next few years.
“Thanks to the collaboration with professional schools and top universities, we are starting an exchange of competencies and research between manufacturers and students who want to learn more about tapping technology,” Mr Sorgato concludes.
“This project is still under development, so I can’t say much more. What I can reveal is that it will be a mutual opportunity for growth, with the students able to rely on our experience and support while we’ll benefit from the fresh thinking and enthusiasm of the students.”
Hall 5, Stand B34
True to the company’s mantra of ‘Shaping the future together’, innovations around digital machining and Industry 4.0 are set to be the focus of the 528m² stand in hall 5 (stand B06).
Of course, hardware in the shape of the latest cutting tool and tooling innovations will also be in the spotlight. Chief among the latest products making the transition from development lab to commercial availability will be an innovative, easy-to-use solution for efficient and reliable drilling.
This breakthrough tool offers high performance at low cost, while simultaneously delivering consistent hole diameters at lower noise levels than existing generation products. The drill will be officially launched on the stand, where visitors will be the first to discover more.
The new-generation lightweight CoroMill 390 milling cutter, produced by additive manufacturing, is no less innovative. Combined with Silent Tools adaptors the cutter reduces, thanks to its lightweight construction, vibration in long-overhang milling, thus increasing stability and productivity.
Beyond the tooling offer being showcased at EMO, the company’s digital solutions enable the interconnection of design, planning and metalcutting, as well as effective process analysis and advancements.
Various CoroPlus digital machining solutions from Sandvik Coromant offer different ways to integrate manufacturing intelligence into a machine shop, resulting in optimised processes and fact-based improvement decisions. For example, the market-ready Coromant Capto DTH Plus, a solution that enables the predictive maintenance of Coromant Capto driven toolholders, will be on display.
One of the highlights at the booth will be the upgraded CoroPlus ToolPath software for PrimeTurning, the recently introduced all-directional turning concept from Sandvik Coromant. CoroPlus ToolPath software is designed to support manufacturers who use PrimeTurning technology in accelerating their operations and planning processes. In addition, the software now provides the option to import CAD models and create 3D simulations with collision detection.
Following this holistic approach, Sandvik Coromant will also present a new solution that enables sensor-equipped tools, such as the Silent Tools Plus solution, to send data directly to the machine. In this way, machining processes can be monitored and controlled in real time.
Another offer from the CoroPlus portfolio is the CoroPlus ToolGuide which visitors to the stand can test out for themselves. This comprehensive solution provides precise tool recommendations and cutting data based on customer specifics, such as workpiece material and application type. The latest addition includes an update with recommendations for boring tools and cutting data.
The newest addition to the Sandvik Coromant collection of apps is the Tool Wear Analyzer app. Whenever a manufacturer is unsure of the cause of an unexpected tool wear, they can simply use their phone to take a picture of the wear and easily compare it with wear types in a repository of images. The app also allows the user to measure the wear and save it or share it with a colleague. The app works best if a microscope is attached to the phone.
Hall 5, Stand B06
Occupying the whole of hall 2, visitors will see the company cover a wide range of technology subjects including: automation, integrated digitisation, news Celos apps; a new customer portal (My DMG Mori); additive manufacturing; and process solutions.
The WH Cell and WH Flex are just two of the 27 automation solutions that DMG Mori will be showcasing at EMO. After the successful launch of DMG Mori Heitec at the end of 2017, several dozen projects are being realised. In future, the company will offer all machine tools in its portfolio with automation solutions in order to meet steadily increasing demand.
Another highlight among the numerous automation solutions in hall 2 is the DMU 65 monoBLOCK with a new AGV (automated guided vehicle), a standalone system for pallet automation. This innovative solution offers a flexible automation layout with free access to the machine and an intelligent safety concept for human-machine collaboration.
Intelligent services and applications with integral connectivity for networked production
For DMG Mori, connectivity constitutes one of the core features on the path to the digital factory, because only open interfaces and standardised communication protocols can ensure future-orientated end-to-end integration and interoperability of machines and processes.
That is why in future all new machines from the manufacturer will be connectivity compliant in their standard versions at no extra cost. The new IIoT interface supports both the standard MQTT and MTConnect protocols as well as the new umati (universal machine and tool interface) standard based on OPC UA.
DMG Mori will be presenting new Celos apps in line with its focus on integrated connectivity. The new Application Connector for example, enables the operation of all web-based applications directly via Celos. So direct interaction with MES or ERP systems is possible as is access to specialised customer applications. The new Job Import feature enables orders to be imported directly from MES or ERP into the Celos Job Manager.
For streamlining service and support, DMG has introduced the new My DMG Mori online portal for interactive cooperation between DMG Mori and its customers.
Among other things, service requests can be initiated at the press of a button via my DMG Mori with the ability to attach images and videos. A ‘tracking and tracing’ function ensures transparency for all service processes and procedures. Even orders for spare parts can be tracked down to the exact minute.
Four complete process chains for additive manufacturing with powder bed and powder nozzle technology make DMG Mori a leader in additive manufacturing. The powder bed machines in the Lasertec SLM series are designed for productive manufacture of complex workpieces. The precision of selective laser melting enables the realisation of complex geometries that would be impossible to produce with conventional methods.
The series includes the successful Lasertec 30 SLM 2nd Generation and the Lasertec 12 SLM which owes its high accuracy to its focus diameter of just 35µm. The fast powder change using the rePLUG powder modules takes less than two hours and Optomet software enables automatic calculation of all process parameters within days instead of months.
As a powder nozzle machine developed primarily for larger workpieces of up to 500mm diameter x 400mm and weights of 600kg, the Lasertec 65 3D hybrid unites the build of workpieces using laser deposition welding and 5-axis simultaneous milling operations in a single set-up. The machine will be on display at EMO.
The new line includes GL 250, GL 300, GL 350 and GL 450 models, and is designed to operate in medium and high production environments. Its robust structure with a monobloc casting bed is ideal for machining requiring high power and torque, ensuring high performance and precision. With the thermal compensation system, stable dimensional results can be obtained even with temperature fluctuations over long working periods. Models offer feed speed of 30m/minute on the X- and Z-axes.
For Romi CEO Luiz Cassiano Rando Rosolen the new generation portrays the company's position on technology: “We seek to anticipate the market need by developing machines that bring significant customer gains, increasing productivity, process accuracy and high technology, indispensable requirements for the new generation of the industry,” he says.
Another differential is the main headstock with built-in motor, a compact system when compared to similar machines. It consists of a motor incorporated in the spindle cartridge whereby the rotor is coupled to the spindle and the stator is presented fixed to the housing itself, thus eliminating pulley and belt, which guarantees excellent power level, high torque at low revs, stability and low inertia.
The GL line is available in four different versions: the T version which is equipped with 12 position turret for fixed tools and servo-driven swivel head; the M version, supplied with a 12 position turret for powered tools and a servo-driven swivel head. The Y-version which comes with 12 position turret and Y-axis with stroke up to 150mm (±75mm), allowing milling, drilling and tapping operations outside the centreline on the main spindle; and finally the version S is equipped with a 12 position Y-axis powered turret, which also features a sub-spindle with built-in motor type, enabling the machining of both sides of the workpiece.
The CNC on all models includes the new HMI control from Fanuc in varying configurations, which offers the ease of programming with conversational machining cycles.
All models can be equipped with several options, such as automatic door, swarf conveyor, mist extractor, wash gun, parts catcher and automatic parts loader/unloader.
Hall 12, Stand D36
The new Micro HD 5-axis machining centre will be presented in combination with the Erowa Robot Compact 80 automatic component loading cell, which is exclusively available in the UK and Ireland from Rainford Precision.
Kern will demonstrate how small, delicate and also large components can be mass produced fully automatically with precision down to the nanometre range, opening wide a new field for cost efficient production.
With a compact footprint, the machine occupies an area of 1,650 by 2,660mm with a height of 2,633mm. The HSK40 spindle has a wide speed range from 500 to 42,000rpm with both through tool coolant or air blast available. This combination enables components to be produced efficiently with excellent surface finishes while also being cleaned before they are automatically stored for the operator.
Component loading and unloading is available with a number of options while the machine at EMO encompasses an external workpiece magazine that can load small as well as large workpieces by automatically changing the size of its workpiece grippers. For customers with small workpieces, these can be held in the tool magazine offering either 30 or 60 workpiece positions, thus reducing the size of footprint even when working automatically.
As a leader in micro precision production, the axis movements of the Micro HD are a combination of linear drives and hydrostatic guideways. This ensures the highest possible level of accuracy and slip slick prevention. Kern says this development permits table movements and positioning to a level of precision and accuracy previously beyond the reach of many manufacturers.
The Micro HD is the latest addition to the Kern family, which currently comprises the Micro Pro and the Micro Vario.
Kern (Rainford Precision)
Hall 12, stand D76