Tough competition from low-wage countries; the outsourcing trend; high taxes; costly compliance with regulations; the indifference of elected officials; a shortage of skilled workers; difficulty attracting young people to the industry: these are the issues facing manufacturers in Europe. They are the same issues facing manufacturers in the United States.

Because these challenges are largely the same on both sides of the Atlantic, the recent EMO show was perhaps more relevant to U.S. visitors than past shows, when differences in the markets were more pronounced. The technology trends apparent at this year’s EMO show in Hanover, Germany, reflect a response to these challenges. Although all of the major machine tool builders introduced machine models never shown before, this show was distinguished by few notable technology leaps. The new machines generally filled gaps in existing product lines; for example, they were of a larger or smaller size. Likewise, an additional subspindle, an extra tool turret, more rotary axes or special options distinguished many of these new products.

High Value-Added Manufacturing

For the most part, exhibitors were focusing on the type of manufacturing least likely to migrate to low-wage countries—that is, high-value added work in which the labor content tends to be relatively low. This involves workpieces that are extremely small or large and heavy, with complex geometry, made of costly or difficult-to-machine materials. Machine features that help reduce setup time, eliminate manual handling or automate operation were emphasized. Combining processes on one machine was a common theme.

CECIMO, the umbrella organization that represents alliances of machine tool builders and technology suppliers in Europe, announced its plans to promote high value-added manufacturing in Western Europe. The comprehensive effort is being called ManuFuture, and it includes several major initiatives designed to move manufacturing from the traditional, resource-based model to a knowledge-based model. The plan calls for individual companies to become more focused on innovation; for national governments to provide funding and create a climate more conducive to investment and innovation; and for research institutions to target their efforts on a coordinated set of priorities.

Multifunction Machines Everywhere

Because setup and parts handling have a direct impact on labor costs, shops are especially eager to adopt technology that allows parts to be completed on one machine in one fixturing. Turn/mill machines and other multi-process machines seemed to be everywhere at this show. Especially noticeable were machines large enough to handle big parts, such as the landing gear for the new generation of jumbo jets or camshafts and crankshafts for heavy off-road construction equipment.

In general, these machines are being designed for heavier milling cuts, faster spindle speeds for turning and greater freedom in rotational axes. Faster automatic toolchangers are also appearing as builders present their second, third or fourth generations of multi-process machines. Turn/mill machines, which were originally pioneered in Europe, are well accepted there. Labor costs are generally higher in Western Europe than in other parts of the world, and factory space tends to be tighter than in the United States. This makes a machine that takes the place of two machines and eliminates extra setups very appealing.

3D models that simulate the turn/mill machine in action ensure safe operation by detecting and avoiding possible collisions. A display of the Crashguard system from WFL Millturn Technologies (Linz, Austria) shows how realistic this simulation can be.

Software For Multitasking

The emphasis on multi-process machines was reflected in many of the notable CAM software trends apparent at the show. Software developers with packages for programming this kind of machine were promoting these products heavily. Features allowing the user to coordinate and synchronize simultaneous machining operations were popular. Developers were also emphasizing the importance of providing reliable and effective postprocessors for multi-process machines. Alliances between machine tool builders and CAM software developers continue to grow, easing concerns about learning how to program multitasking machines.

Perhaps the most interesting development is software for simulating the multi-process machine in operation. Using solid models of the machine, the workpiece and cutting tool, this software allows a virtual dry run of the part program to detect potential collisions or clearance issues. Because these machines are increasingly being applied to shorter runs, being able to create efficient part programs and use them confidently is a real boost.

Multitasking Cutting Tools

Cutting tool manufacturers are complimenting multi-process machines with multi-process cutting tools. By combining positions for several carbide inserts on one cutter body, for example, the combination creates a “mini tool turret” that frees up pockets on crowded tool turrets for additional tools. These combo tools also require fewer trips to the automatic toolchanger or indexing of the turret, thus reducing cycle times.

A theme repeated in several booths was the importance of considering cutting tools strategies early in the planning process for applications on multitasking machines. Machine tool builders and cutting tool manufacturers are working together to promote the innovative use of cutting tools to get the most out of multitasking machine tools.

One Step Ahead

EMO proved that grinding is holding its own. Although hard turning continues to take some work away from grinders, the latest generation of grinders is creating applications that take grinding to a new level in terms of speed, accuracy and flexibility. So whatever grinding loses to hard turning or other processes, it regains by opening possibilities that did not exist before. To note one example, by taking light cuts at high speed, grinding of titanium can be accomplished without causing heat damage to the material. Grinders that can maneuver in five simultaneous axes make contouring of very hard or brittle materials a viable process.

Grinding is a dynamic area in which high-end grinders are becoming the machine of choice for the difficult applications on which shops are pinning their hopes. Manufacturers in Germany are especially likely to find the finesse and discipline of advanced grinding to have strong appeal, and they will no doubt leverage this capability to their advantage while manufacturers elsewhere eschew grinding as a difficult and demanding process.

CNCs Reaching Up . . . And Down

Many of the new machine tools on display at EMO take advantage of new developments in CNC technology. High-end machines are leveraging the capability of high-end CNCs, obviously. Control units with the speed and power to handle the demands of 3D simulation software are the most striking evidence of this trend.

Cutting tools dedicated to multitask machining help users get the most out these capable machines. The CoroPlex line from Sandvik (Fair Lawn, New Jersey) shows how multiple insert positions let one holder perform several operations.

What might be overlooked, however, is that the major European and Japanese control builders have also given basic and toolroom machines a big boost. Enhanced user interfaces for mills and lathes streamline the shopfloor programming of parts that were formerly considered best handled by experienced off-line programmers. Especially welcome are systems that allow non-CNC machine operators to move up to near or full CNC mode on machines designed for both manual and fully programmable operation.

Several machine tool builders also had new CNCs of their own to demonstrate at the show.

Finally, the networking capabilities of CNCs at all levels were getting a lot of attention. Production plants, which often have very simple and very complex machines in the same line, are interested in connecting all of these machines in a plant-wide network. Control builders are facilitating this connection by offering a common interface for communication with operators as well as features for automated reporting of happenings inside the control system, whether the control system is basic or advanced. Internet-enabled technology that allows remote monitoring of machine performance was also a common theme.

A Boost To Service And Support

A significant number of machine tool builders based in Europe are promoting their increased emphasis on service and support. There are several reasons for this. For one, builders are aware that this has been a weak spot in the past, and now they have the resources to address this weakness. For another, buyers are looking more closely at how well a machine tool builder can provide service, spare parts and application support.

As machine tools become more capable, more flexible and more productive, many shops are relying on fewer machines and counting on them to be in production more hours per day, more days per week. Unplanned downtime poses a major disruption to work flow, which is especially damaging in situations where work in process is being kept to a minimum. Moreover, many buyers do not have the same level of engineering or part programming personnel as before, so they are looking to the builder for help with application development and training.

Builders, in response, are setting up more technical centers, bolstering inventories of spare parts for fast delivery, developing remote monitoring on networks for diagnosis and repair, and partnering with other builders to share service and support resources. The importance of a strong service organization in the United States is getting special attention because vast distances compound the service challenge in this country.

Return To Hanover In 2007

The mood among exhibitors was buoyant. Machine tool output and consumption are up around the world, with many builders expecting 2005 to close as one of the best years in a decade. There is a good chance that new product development will continue to accelerate as greater revenue permits a stronger R&D effort. We can look for more dramatic innovations to appear at the next major international technology shows such as IMTS, JIMTOF and the next EMO.

EMO 2007 returns to the Hanover Fairgrounds in Germany. This marks the new cycle of show sites that now takes effect. After that, the show goes to Milan and then back to Hanover; Paris is no longer part of the rotation.