AMB 2024: Digitalization in the metalworking industry

Digitalization in metalworking has been an important topic for years. At AMB 2024, exhibitors will demonstrate that there are already many solutions for tackling the issue of digitalization in companies.

"As things stand today, the level of digitalization at store floor level is still shockingly low and, if at all, characterized by isolated solutions." This statement from a survey participant among exhibitors at this year's AMB shows the perception of the basic level of digital maturity in metalworking. All too often, machine and plant manufacturers still say: "It's only a matter of time before the knot will burst..."

Despite the obvious reluctance of many users and failed attempts to establish digital platforms, Industry 4.0 and IIoT are no strangers to mechanical engineering and metalworking in 2024. Everything is in place to tackle modern concepts. With OPC UA and Umati, a customized, universal machine tool interface has been available for years. With 5G campus networks, a powerful private mobile communications standard is available for networking machines and systems. And the know-how is also available. Just one example: control technology providers such as Fanuc, Heidenhain and Siemens have long been demonstrating the benefits of digitalization in daily use in related manufacturing sectors.

It is therefore not surprising that many participants in a survey of AMB exhibitors also emphasize the topic of digitalization. At this year's international exhibition for metalworking in Stuttgart, they want to prove that integrative digitalization approaches are already part of today's world - especially the software providers. For example, Evomecs, which was founded in 2015, networks machines, systems and processes in a brand-neutral and location-independent manner. The Munich-based company sees itself as a driver of digitalization in order to counter the increasing pressure to rationalize, the growing shortage of skilled workers and intense international competition. Those companies that succeed in initiating the right measures today will be more successful as production companies in the future, but also more resilient, as they will be able to expand their value creation to digital business models.

The Evomecs software integrates all relevant components of a machining company, such as ERP systems, CAM systems, tool presetters, tools, workpieces, storage systems, CNC machines and manual workstations. The ecosystem created in this way generates a lot of high-quality data about the company's own manufacturing processes. In principle, this data can also be used for the development of data-supported or data-driven business models, according to the company.

Manufacturing companies need to produce faster and more efficiently. Particularly in the production of small quantities, this results in an enormous amount of communication, administration and documentation, which can easily lead to expensive errors and damage in production and requires a high level of expertise along the entire production process. Evomecs is convinced that companies need to optimize, automate and therefore also digitalize, especially in light of the increasing shortage of skilled workers.

With the help of Evomecs software, a valuable treasure trove of data is created that can, in principle, form the basis for a wide range of applications, such as artificial intelligence. Users can generate information from production that can be used to optimize processes. Work is currently underway in Munich on concepts that enable data analysis, process optimization, planning forecasts and, for example, voice-activated production control.

Digital solutions also offer great potential for optimization at the heart of the machine, in the machining process itself. Modelling and simulations optimize subsequent operation and enable higher cutting speeds and feed rates as well as a longer tool life. CAE provider Third Wave Systems provides virtual test environments that lead to less downtime and eliminate the need for trial-and-error tests.

At AMB 2024, the company will present technical innovations that significantly reduce time-to-market. Visitors will be able to experience how virtual iteration significantly reduces both the number of trials and errors compared to trials on the machine. This leads to a sound design-for-manufacturing process with a focus on "first-time-right". According to the company, the reduced workload for manual post-processing reduces machine run times by 50 percent.

However, the challenges still include users gaining a full understanding of the strategic rationale behind the required mindset shift to a fluid, flexible simulation technology. In the end, according to the company, material-specific modeling and simulation technology pays off. The US company is already receiving this feedback from the aerospace, automotive and orthopaedic medical technology industries.

Digitalization is also part of everyday working life at Grob-Werke. At this year's AMB, the focus will be on the digital tool cycle. This is particularly relevant for tackling rising production costs in a meaningful way. For this reason, the corresponding area of the family-owned company from Mindelheim is dedicated to the automation of tool-related processes this year. Through numerous collaborations with manufacturers of tool management systems and presetting devices, Grob offers users the opportunity to achieve significant cost savings in the handling of cutting tools. The underlying solution is called GROB4TDX and enables the digitalization of the tool cycle throughout production, regardless of the machine manufacturer. According to the company, this is an essential step towards cost-effective and resource-saving production.

Another machine manufacturer is also emphasizing innovations in the digital field in addition to hardware. MTE Deutschland produces bed-type milling machines and traveling column machines. The SBM 8000 fixed-bed milling machine will be exhibited at the AMB in Stuttgart. It is so named because the rigid table, which can be mounted over the floor, ensures high basic stability. However, a significant step towards digitalization in the manufacturing industry is seen in Montabaur for another reason: This machine is equipped with the latest Heidenhain TNC 7 control system. This technology offers functions that significantly increase both efficiency and productivity in CNC machining. CAD/CAM data is seamlessly integrated, making the programming of workpieces faster and more precise. The intuitive multi-touch operation and graphical user interface simplify operation and significantly improve the user experience. In addition, the TNC 7 control offers a range of smart functions, such as automatic workpiece probing and graphical support when aligning clamping devices. These functions simplify the set-up process and optimize workflows. According to the supplier, the result is greater efficiency and precision.

A young company also has lean work processes in mind. Spanflug Technologies is a spin-off from the Technical University of Munich and the Institute for Machine Tools and Industrial Management. Founders Markus Westermeier and Adrian Lewis pursue the platform approach: they bring together manufacturing companies that produce parts in a digitalized workflow. The network now consists of more than 300 qualified manufacturing partners from Germany and Austria. The promise is that users can find the ideal supplier for any CNC part and produce or deliver it within six working days. As preparing quotations for turned and milled parts also takes a lot of time and resources, the idea behind the business model was that automating administrative tasks could be much easier than optimizing production itself.

However, complex tasks such as automated costing for machining cannot be completed in a short space of time using ready-made AI models or purchased software components. This requires patience and the right mix of industry knowledge and technological expertise.

Today, the platform offers two approaches: a procurement solution for users and a quotation solution for contract manufacturers. The former are intended to save costs and production times for machining. Manufacturers benefit from using the platform by avoiding complex IT projects and large investments. The founders are proud to bring together component requirements with specialized manufacturing companies and their more than 6,000 machines. The digital platform enables the most efficient use of valuable resources in the network, balancing loads and avoiding downtimes.

At AMB, Spanflug will be presenting an extended version of the software that outputs a work plan in addition to production times and prices. On the one hand, this makes the calculation easier to understand, as the automatically calculated costs and production times can be viewed according to work steps. On the other hand, users are even better supported in their work preparation. "This completely new approach means that all production-relevant information, such as the required machine tools and work steps, is already available at the time the quotation is created and can be easily transferred to ERP systems," explains Dr. Markus Westermeier, CEO of Spanflug.

The Siemens Group is turning its attention back to the production halls of companies: Replacing machines in a production facility can lead to bottlenecks and delivery delays when capacity is well utilized. A situation that puts many a production manager in a quandary: you need the new machine with more capacity and performance as soon as possible, but you don't actually have time to replace it. This is because it is not uncommon for hundreds of CNC programs to have to be transferred from old to new control systems, even from the same manufacturer. Siemens engineers have asked themselves how production can continue without interruption when replacing an existing machine. The offline programming tool SinuTrain from Siemens offers a solution. This "virtual CNC" behaves exactly like the real CNC in the machine: the same Sinumerik Operate version works here as on the corresponding future machine, with the same machine data from the real machine. The consistency and syntax of the CNC programs can therefore be tested in advance in the best possible way.

In addition, the SinuTrain user has access to exactly the same CNC editors as on the machine. This means that the operating and programming know-how of the specialists on the store floor can be used for work preparation. As a result, the new machine corresponds exactly to the behavior of the virtually prepared machine from day one. A solution that would not be possible without the digital twin.

Software solutions also optimize the ordering process for materials that are to be processed. Take Bikar Aerospace, for example: since 2016, the company has positioned itself as a metal service center for the aerospace industry. All services relating to material procurement, preparation and delivery are offered from a single source. The aim is to offer the fastest possible response to material call-offs and planning by users. A contract monitoring tool provides real-time data on stock levels and enables a constant comparison of the goods required at individual locations with the stock levels at Bikar. This forecast monitor ensures a reliable overview of the supply chain at all times. This enables users to react to uncertainties on the global market at an early stage. The aim is to pave the way for the digital future of the metal trade by developing our own software solutions and intelligently networking our systems.

These examples with different approaches to the digitalization of the metalworking industry show the breadth of the market despite some reticence. This will also become clear at this year's AMB from 10 - 14.09.2024 in Stuttgart. Digital concepts will be a common thread running through the exhibition, linking machine tools and their control systems, automation solutions for all aspects of the machines, embedded measurement technology and collaborative robotics. In this way, digitalization is driving the industry forward on the path to more sustainable and efficient production and to being able to compete internationally. (OM-8/24)