How can European manufacturing companies succeed in global competition? One
particularly effective method is the continuous development and application of innovative
technologies. If these can then also be labelled ‘high-tech’, it becomes even more difficult
for other manufacturers to copy the technologies. It is important to develop and maintain
this head start, so that it can be turned into a competitive edge.
Industrial suppliers and research institutes show how it is done. These and many more
innovation boosters can be found at EMO 2025 in Hanover, from precision tools and high-
tech machine tools to the integration of simulation analyses.
Genuine technological progress is often demonstrated in the perfection of already proven
products through further development. Here is an example: one of the biggest challenges in
internal machining – depending on the material – is long chips. They wrap around the tool,
clog bores or, in the worst case, lead to tool breakage. Chip-breaking geometry can help,
guiding and shaping the swarf and causing it to break.
In the past, specially lasered or ground chip-breaking geometries were used for this
purpose, which entailed corresponding costs for the cutting insert. Cutting tool
manufacturer Horn has now succeeded in developing a universal boring tool with sintered
chip-breaking geometry. The geometry can be used universally for different material groups
and is suitable for internal, face, copy and reverse turning.
Managing director Markus Horn knows the technical and economic challenges in the
machining environment and is therefore enthusiastic: “This precision tool pushes the limits
of today’s technology. It took around four years of development time with numerous tasks
relating to both the process and the materials. In the end, we managed to achieve a cost-
effective solution to the problems caused by long chips in the internal machining of small
bore diameters.”
In addition to the geometry, Horn has optimised the blank of the cutting insert thanks to
greater rigidity and an even more stable cutting edge area. The cooling supply has also been
revised.
The wide range of applications for the cutting inserts is reflected in their cost-effectiveness:
According to Horn, the costs of the new tool are similar to those of standard cutting inserts
without geometry.
“This development shows how technology can set you apart from the global competition in
terms of technology, economy and price,” concludes Matthias Rommel, also a managing
director at Horn. “EMO 2025 is the ideal platform for Horn to present its innovations to
international manufacturing specialists in person.”
It is becoming increasingly important for machining companies to manufacture components
in a single clamping operation. Accordingly, there is demand for powerful five-axis machines
that can perform a wide range of turning tasks just as efficiently as milling work.
According to Dr Manuel Gerst, head of development at machine tool manufacturer Heller,
this is a trend that is gaining international significance: “The proportion of turning
performed on our appropriately equipped machining centres is already around 30% and will
increase to around 40% in the future.”
Reason enough to raise the essential basis for such turning work to a whole new level. With
‘mill-turn-enforced’ technology, engineers from Heller say they have succeeded in
developing a direct-drive rotary table offering exceptional performance data. It will see use
in all of the company’s five-axis machines in the future. It has already been used successfully
in a Heller machining centre (BAZ) since autumn 2024. Another five-axis machine, including
the rotary table, will be available on the market in time for EMO 2025.
But what does ‘exceptional performance data’ mean? The biggest challenge is to achieve
equally high torques and speeds.
“That’s exactly what we’ve managed to do,” says Gerst, presenting the figures: “With the
new table, we can achieve up to 1250 Nm and up to 1140 rpm. These values are around 20%
higher than what is typically available on the market. This enables manufacturing companies
to achieve enormous chip removal rates.”
Heller engineers have made many adjustments to achieve this. For instance, to keep heat
under control, a specially optimised torque motor is used that generates only minimal heat.
The same applies to the bearing.
Another machine tool manufacturer, Hermle, will present several five-axis machining
centres with automation solutions, as well as a five-axis machining centre as a mill-turn
variant. On this mill-turn machine, components are milled, turned, drilled, ground, butted,
deburred, smoothed, countersunk and measured. In other words, 13 productive processes
for the complete machining of complex components are combined in a single clamping
operation.
“It goes without saying that all the products on show will revolve around the two dominant
themes of automation and digitalisation,” says Marketing director Udo Hipp.
The automation of machining centres is a steadily growing market in view of the acute
shortage of skilled workers. From pallet changers to handling systems or the ‘premier class’
of adapted robot systems: Hermle is available to provide advice as well as process-related
support.
“We hope that EMO will live up to its reputation as the world’s leading trade fair and attract
numerous international visitors,” says Hipp. “We offer high-precision three, four and five-
axis machining centres plus full automation and digitalization for ’round-the-clock’ use. At
EMO 2025, we’ll be demonstrating our expertise in milling, drilling and turning.”
Professor Dirk Biermann, institute director at the Technical University of Dortmund,
confirms the enormous importance of always being technologically up to date: “The
Institute of Machining Technology ISF has been conducting research into all relevant
machining topics for over 50 years. In addition to basic research, we also carry out process
technology and industry-related research projects.”
The following examples illustrate the range: high tool temperatures during machining
accelerate wear and shorten the service life of the tools. Knowledge of the temperatures
can both increase process understanding and contribute to the validation of chip formation
simulations.
“At the ISF, we have therefore developed an innovative method that enables chip surface
temperatures to be determined under operating conditions,” reports Biermann.
He adds: “Another project deals with internal turning, which can only be carried out at a
shallow machining depth due to the projection of the tools, especially for smaller bores. We
have subsequently developed a new type of tool system that enables internal contouring
even in long, deep bores.”
This system integrates into the machine tool as an additional axis and has a strip-guided tool
head that prevents oscillations.
“Furthermore, the simulation-based prediction of process behaviour can help with the set-
up of optimised process configurations at an early stage of the value chain,” concludes
Biermann. “In the ‘ClusterSim’ research project – together with project partner AG Virtual
Machining at TU Dortmund University – machine learning methods are being developed and
applied in order to make data-based predictions for individual segments of complex
machining processes.”
As a member of the Academic Association for Production Technology (WGP), the Dortmund-
based institute will be exhibiting together with other WGP institutes on the joint
‘Sustainability’ stand at EMO Hannover.
“EMO 2025 is a unique platform to discuss these and many other current developments at
expert level,” stresses the professor.
More information www.emo-hannover.de/en
