By Liz Stevens, writer, The American Mold Builder
CNC machining was developed in the late 1940s and early 1950s. Like the computing equipment that controls a CNC machine and drives CAD and CAM technologies, CNC machining has evolved dramatically since its early days and continually is improved to meet the industry’s latest needs. CNC equipment manufacturers respond to requests from their customers for new features and expanded capabilities. They respond to technological advances such as Industry 4.0, the Internet of Things and additive manufacturing, while keeping a watchful eye on local, regional and global developments that may impact the machining and mold building industries.
The American Mold Builder interviewed representatives from two CNC equipment companies to learn about new developments, integration with other technologies, security issues and more. Makino Inc., established in Japan in 1930, has its Americas headquarters in Mason, Ohio. Makino offers a family of CNC machining centers with metal-cutting and EDM machines in configurations with 3-, 4- and 5-axis machining. PROMAC North America Corp., with US headquarters in Troy, Michigan, was established in Italy in 1995. PROMAC offers four lineups of CNC machine tools – fixed portal, gantry machine with fixed table, rotary-translating table and horizontal travelling column machines – in completely customizable working centers. The American Mold Builder also gathered insight from Siemens on the company’s newest CNC control features.
What new technology developments are coming in the near future for CNC machining/equipment? What about in the long-term?
Sean Shafer, market segment manager, Makino Inc.: “5-axis technologies, advanced tooling and ease of programming have been huge improvements in the last 10 years, enabling higher utilization of 5-axis CNC machines. Cutting machine tool technologies have peaked in terms of maximizing machining speeds; further speed increases would not bring significant cycle time reduction and likely would cause inaccuracies due to thermal heat and mechanical vibrations.” Shafer cited digital twins as the future for manufacturing. “Digital twins incorporate a CAD model of the entire shop, and the machines, processes and skillset efficiencies, allowing machine kinematic selection for the parts through AI.”
Giulia Carraro, administrative manager, PROMAC North America: “PROMAC’s machining centers are known for their flexibility of use due to their characteristics, some of which are patented, and to our in-house development and production of automatic heads and related electro spindles.” The PROMAC features meet machining requirements in a variety of fields, including moldmaking, special general mechanics and the aerospace sector. “With these features that set us apart,” said Carraro, “PROMAC machining centers can be configured to integrate combined machining – such as turning and milling – in a single set-up and with automatic head and pallet changing systems. These machining centers also are suitable for large dimensions pieces and can allow unmanned production over long periods.”
Siemens Corporation: “Siemens is expanding its offering on the SINUMERIK ONE ‘digital native’ CNC. This new control generation now is being offered with innovations in hardware and software. With the new system software SINUMERIK V6.20, there are new technology functions for SINUMERIK ONE that simplify machine tool operation, reduce machine wear and increase manufacturing productivity. With these developments, Siemens is demonstrating how the SINUMERIK control system can be optimally used for digital transformation in a highly productive, flexible and modular way.”
How does Industry 4.0 play a role in equipment advances? What is an example of How Industry 4.0 features are incorporated into equipment? How are the cybersecurity concerns that come along with digital connectedness and remote access addressed?
Sean Shafer, Makino Inc.: “Makino offers Machine Condition Monitoring software, which provides predictive maintenance actions for uptime reliability. It also provides for managed maintenance to best work around any downtime.” Shafer explained that the software includes three levels of connectivity – standalone control, company private network or cloud-based connectivity.
Makino is very aware of the cybersecurity issues that come with increased connectivity. “Many shops remain nervous about storing their data and intellectual property in the cloud,” Shafer said. Some companies are ITAR-certified – dealing with defense-related items – and so they are restricted as to what they can do with their data. “With so much data now coming from the machine tools,” said Shafer, “the current issue is how to manage the massive amount of data. We expect that AI will assist with that issue.” To safeguard systems while allowing authorized remote access, Makino’s controls use white list antivirus protection and will only run programs on a control that the customer has authorized.
Giulia Carraro, PROMAC North America: “The interconnection of work centers with management and data analysis software makes it possible to analyze and improve production processes and achieve maximum yield both in terms of production process and return on investment.” PROMAC believes that in today’s production system where the comparison with competitors is global, Industry 4.0 integration is crucial for efficiency which, consequently, improves competitiveness. “The system of connections, stored data and related processing is part of the company’s assets,” Carraro asserted, “and therefore must be managed with appropriate secure access and safeguarded storage systems. PROMAC uses remote connection systems and software from specialized companies that provide secure, protected connections based on the specific authorization of the end customer.”
Siemens Corporation: “SINUMERIK ONE plays a central role in the transformation of machine tools in the age of Industry 4.0, outperforming previous generations of controllers in terms of PLC and CNC performance in machine operation, cutting speed, data capture and processing power. With its integrated SIMATIC S7-1500F PLC, it offers up to 10 times faster PLC cycle times. With the SIMATIC S7-1500F PLC, SINUMERIK ONE now is fully integrated into the Siemens TIA Portal engineering framework, enabling standardization of all engineering tasks for operators of larger plants.”
As an equipment manufacturer, what is the biggest “ask” received from customers for new features or expanded capabilities (i.e., equipment speed, changeover rates, etc.)?
Sean Shafer, Makino Inc.: “As already mentioned, increased speed is no longer a request that we receive from customers. Nowadays, the requests are more about reliability, repeatability and consistency.” In response, Makino offers Machine Condition Monitoring software to address these issues. “And,” said Shafer, “most of our 5-axis machines now feature Collision Safeguard to avoid spindle collisions.”
Giulia Carraro, PROMAC North America: “In addition to building precise and reliable machining centers, our customers increasingly are turning toward flexible manufacturing systems, complete with automatic pallet or head change systems so they can be used continuously and unattended. The new generation of PROMAC machining centers is available with systems for monitoring machining status and usage so that they can continuously check whether they are within the set parameters. Special sensors in the various electronic and mechanical components allow maintenance to be managed in a predictive manner.”
Following the supply chain meltdown during the pandemic and with a current political focus on empowering American domestic manufacturing, what kind of business decisions are being seen by customers and prospective customers? Is there a push to reshore moldmaking?
Sean Shafer, Makino Inc.: “We are not seeing an increase of moldmaking reshoring to the USA. Most of the large die/mold shops still are using overseas resources, and most of them also have facilities in Mexico. The Big Three, however, now are requiring supply chain resiliency. They are shifting sourcing from China to alternatives like Mexico, Vietnam and India.”
Giulia Carraro, PROMAC North America: “Undoubtedly, we are facing a new industrial era where innovations often are slowed down by obsolete and slow production processes, and influenced by issues that are not just industrial but also by political, climate-related, and health or social concerns as well.”
“Shortening the supply chain is a solution that helps a lot,” said Carraro, “but it is not always enough. It also is important to have a technical support system, available remotely and in person to the customer, to reduce any possible downtime. PROMAC has invested in this from the start, by having a local office in Michigan and by thoroughly preparing and training our dealer technicians.”
How are companies evolving to include additive manufacturing (am) equipment options and to incorporate AM as another tool in overall systems?
Sean Shafer, Makino Inc.: “Makino has an Additive Manufacturing Services Group in Singapore that is dedicated to developing the entire AM solution, including removing part fixturing, machining and automation. They are developing additive machines, laser machines and materials to support AM. We are seeing additive manufacturing as a process that can create unique, unmachinable cooling inserts to provide 25 to 35% faster cycle times.”
Giulia Carraro, PROMAC North America: “In keeping with PROMAC’s logic of integrating into machining as many processes as possible so that they can be executed in sequence with a single workpiece placement, the company makes additive processes available in addition to subtractive processes, at the customer’s request and in conjunction with our technical evaluation.”
As an indispensable technology for mold builders, the manufacturers of CNC machining equipment will continue to expand the equipment’s capabilities, finetune its operations and incorporate automation to meet the industry’s evolving needs.
For more information, visit www.makino.com, www.promac.eu and www.siemens.com. For information about the AMBA CNC Users Group, visit www.amba.org/events.
AMBA CNC Users Group Debuts
As Tom Barr mentioned in his president’s message in this issue of The American Mold Builder, AMBA created a new benefit at the end of 2023 for CNC companies and teams – an online CNC users group has roundtable discussions and meetings the second Thursday of every month. Barr was enthusiastic about the group’s initial meetings and its value to CNC companies. “The first meeting was about the use of test cutters,” said Barr, “and the second meeting’s topic covered ERP systems and how they are utilized in the CNC area.” Barr’s team was very receptive to the roundtable discussions – an opportunity to gain knowledge while sharing their own ‘pro tips.’ “What a great way for the moldmaking CNC community to introduce topics that are a challenge and to learn from someone who’s already encountered those challenges,” said Barr.