The well-known software suite, MCOSMOS, is recognized as the go-to data processor for Mitutoyo’s range of top-of-the-line CMMs. Supported by an extensive line-up of optional software applications, users have full control over a wide range of probe systems ready for any kind of workpiece.
MCOSMOS helps you carry out all your measuring and test jobs at lightning speed, simply and safely. MCOSMOS handles large amounts of data with ease, making it available across all the networked areas of the production chain. This streamlines the measuring process, optimizes the flow of information and minimizes non-conformances. The result is increased efficiency throughout the production process with significantly reduced costs.
With its specialist expansion modules, MCOSMOS can focus on your company’s very specific measurement requirements. With Mitutoyo software, you are best prepared for every imaginable 3D coordinate measurement challenge, both now and in the future with maximum flexibility.
MCOSMOS is the smart software platform from Mitutoyo, setting international standards for sophisticated 3D coordinate measurement. With MCOSMOS, your coordinate measuring machines become efficient information centers – powerhouses of design, production, and quality control. Streamlined measurements, as well as convenient and reliable data, are at your fingertips throughout the production process.
Modelled with a modern design, this New Graphical User Interface (GUI) improves on the previous version with a simplified and attractive module display, while an Improved Search Function has been designed to assist users in their quest for specific elements of their measuring program, and thus editing has become even easier when compared to version 4. Added in this new version of MCOSMOS, is the possibility of using a 3D Display Of The Geometry And Microstructure of technical surfaces including visualized tolerance zones, providing operators with a more detailed overview of the workpiece.
The function “Support of Two-Point Size Of Planes according to ISO 14405-1″ gives MCOSMOS the capability to evaluate the two-point size of two selected planes, which both were calculated by least squares (Gaussian) method.
A large amount of progress has been made in Mitutoyo’s Optimization For Large CAD Files over their previous versions of software, lowering process time and improving the overall operation of MCOSMOS and toolbars are replaced by Ribbon Control, Including Contextual Tabs.
For more information, please contact RGC Engineering – Tel: 011 887-0800.
The world premiere of the S23 and ground-breaking grinding technologies underline the innovative strength of the Swiss cylindrical grinding specialist for the competitiveness of its customers.
“Fritz Studer AG looks back on a successful EMO 2025 in Hanover. We are delighted that our innovations in grinding technology attracted such great interest from international trade visitors,” said CEO Sandro Bottazzo. The Swiss manufacturer of high-quality cylindrical grinding machines presented numerous innovations at the world’s leading trade fair for manufacturing technology from September 22 to 26.
World premiere of the S23 and new generation of favoritCNC
A highlight was the world premiere of the new S23 universal cylindrical grinding machine. This versatile CNC machine offers state-of-the-art grinding technology for maximum precision and reliability in a space-saving design. Thanks to its high-quality features, the S23 perfectly complements the portfolio between the entry-level and premium segments. It impresses with features such as the modern CORE hardware and software architecture, an automatic B-axis with 1° Hirth gearing for up to three grinding tools, and a Granitan® machine bed with outstanding thermal and vibration properties.
The new generation of the favoritCNC, which STUDER has equipped with modern capabilities and optimizations, also garnered significant attention. The popular entry-level machine now features an updated CNC control (FANUC 0i-TFP), an automatic operator door and loader interface for automation solutions, a resource-saving belt-driven spindle system, and a machine frame with a larger X-guideway spacing for even greater stability. Furthermore, the new Conventional Mode facilitates the transition between manual and CNC grinding.
Innovative axis system and WireDress® for internal cylindrical grinding
On the S31 universal cylindrical grinding machine for small to large workpieces, STUDER demonstrated an innovative axis system that sets new standards in automated precision cylindrical grinding. The long W-axis enables automatic adjustment of the tailstock position to different workpiece lengths, while the active R-axis, equipped with an in-process measuring system, can scan complex geometries on the workpiece. A special feature of the system is the direct measurement of the clamping force. This ensures precisely reproducible clamping conditions for workpieces. The clamping force is also displayed on the control screen for the machine operator.
A further leap in innovation was presented with the introduction of the WireDress® non-contact dressing system for internal cylindrical grinding. This wire EDM-based technology opens up new geometric manufacturing possibilities with diamond and CBN grinding wheels featuring a sintered metal bond. This is made possible by a new internal grinding spindle capable of transmitting current at full grinding speed.
“At EMO 2025, STUDER was able to demonstrate how we will continue to contribute to our customers’ success in the future. A smart combination of reliable and innovative grinding technology offers decisive advantages for competitiveness,” summarized Pascal Schärer, Sales Manager for Central Europe.
The new axis system for the S33 and S31 enables automatic adjustment to different workpiece lengths.
For further information, please contact RETECON – Tel: (011) 976 8600.
Laser cutting with speed – Automated loading and unloading of laser systems
The ByTrans Modular is an advanced loading and unloading automation. It injects extra speed into your Bystronic laser cutting machine, both for large series and for small jobs.
The variety of configurations and layouts allow choosing the best solution. This eliminates the need for manual loading and unloading. The system takes care of it for you.
Straightforward control – User-friendly touch screen
The new software features enable you to easily control your automation from the touch screen of your laser cutting system. In addition to the standard scope of supply you can also connect additional control panels to have a better overview and management of the overall cutting cell.
Automation drives high productivity – Perfectly tailored to your requirements
The ByTrans Modular offers you an extremely high level of configurability, allowing you to choose the best solution to improve the productivity of your laser systems, easing also your operator’s workload.
The ingenious system architecture enables native interfacing with Bystronic’s next-generation storage solutions. Reach the next level of productivity by connecting the system to BySort. You can even use your ByTrans Modular to manage two laser systems within the same automation setup.
For more information, please contact Cutronic – Tel: 010 410 0200.
Increase your level of automation with Bystronic’s BySort
BySort is the new extension module for the ByTrans Cross loading and unloading automation system. The upgrade sorts the completed cut parts and thus accelerates the automation cycle of all the processes related to fiber laser cutting.
With the newly developed BySort upgrade, the ByTrans Cross is now an even more versatile unloading solution. An additional bridge is installed on the ByTrans Cross system, which can accommodate up to two sorting heads. These heads are automatically tooled using the available gripper modules.
The BySort is designed to deposit the completed parts on an additional unloading position next to the laser cutting system, which offers ByTrans Cross users an even higher degree of flexibility. Amongst other things, this supports users with the processing of large series where the individual cut parts need to be unloaded and sorted separately according to jobs. The repetition accuracy with which the BySort deposits the parts is a great advantage. Particularly with large cut parts, this is difficult to achieve manually. The accurate positioning of parts on palettes facilitates the automation of subsequent processes, because it allows the precise position detection of the parts to be further processed.
Moreover, BySort increases the speed of the entire unloading process. Bystronic achieves this thanks to the efficient design of the system unloading routes. In a first step, BySort unloads and sorts the cut parts. Subsequently, using a different route, the ByTrans unloads the residual sheet. This ensures that the laser cutting system’s shuttle table is more quickly available for the loading of the next sheet, which the ByTrans Cross fetches from its own stock or from the connected warehouse.
Integrated control on the touch screen
Both, the BySort and the ByTrans Cross are controlled using the laser cutting system’s touch screen. To achieve this, Bystronic developed the ByVision Cutting user interface, which is already being used with the latest generation of Bystronic’s fiber lasers. ByVision Cutting integrates all the cutting processes and the connected automation solutions. During everyday production this allows laser cutting and the automated material feeding and removal process to be closely interlinked. Nowadays, no user should waste time, walk long distances, and carry out unnecessary procedures, just because the laser cutting system and the connected automation solution have to be operated using separate terminals. After all, for the operator, automation also means convenience.
For more information, please contact Cutronic – Tel: 010 410 0200.
By Paul Savides, Managing Director, PBS Machine Tools
Generally, to meet High-Mix Low-volume production, you require numerous standard machining approaches that need to use drawn-out, multi-step processes with single-spindle machines, which are not a great fit for high-precision engineering shops, especially, those looking to expand from one-offs to production orders.
Paul Savides Managing Director, PBS Machine Tools
Parts with complex milled features or multiple milled faces that require a secondary machining operation on a separate machine after initial turning not only extended cycle and setup times but also introduced the risk of tolerance stacking and alignment errors, due to re-fixturing or relocating to the second operation. Even parts with seemingly larger permitted tolerances can require closer attention to dimensional stacking, demanding even tighter tolerances.
As an example, to make medical parts, even in the hands of a skilled machinist, creating the tool paths that can accurately machine these part shapes, is ineffective. Unfortunately, the part geometries are mostly outside a standard CNC machine’s capability range, due to time-consuming processes on single-spindle, single turret machines.
Multitasking – Where High Requirements Meet High Volumes
Purchasing a Multi-Tasking machine to handle complicated turning geometries like gear cutting, five-axis work and more.
Twin-spindle, twin-turret setups with live tooling and Y-axis machining capabilities provide more flexibility than most machine shops are familiar with.
While machine rigidity will prove useful right away for you, it will take time before you fully trust the machine’s advanced features and then fully utilize them. By cautiously experimenting with simultaneous Pinch-Turning and Pinch-Milling, you will be amazed how processing this way maintains tight concentricity and straightness, especially on long, thin parts and how it cuts cycle times, by enabling simultaneous roughing and finishing operations.
Pinch-Turning can also reduce setup times by eliminating the need for steady rests and rotating centers for some operations, making you more agile and efficient as it progressively allows for increased annual part volumes.
New Features, New Parts
High Dynamic and Eccentric Milling capabilities sharply cut setup and cycle times, and therefore, by taking advantage of Tongtai Group’s numerous Multi-Tasking solutions that provide rigidity, advanced cutting features and a done-in-one architecture to reduce setup and cycle times, will make you more competitive.
Our TMS series represents Tongtai’s commitment to process integration and machining efficiency. Designed as a full multi-tasking turning center, TMS combines live tooling, symmetric Y-axis movement, dual spindles and substantial structural rigidity, making it ideal for gear machining and complex shaft-type components.
The C-axis indexing accuracy and servo synchronization between spindles ensure precise angular positioning , essential for gears and coupling components. Five-axis milling integrated into a multitasking platform, significantly reduces the need for multiple setups and fixturing and will have a substantial impact on repeatability, throughput and overall process efficiency, especially for high-value, low- to mid-volume components.
Cycle times can be reduced by up to 50% and setup time by up to 75%, depending on part complexity.
High Dynamic and Eccentric turning can be particularly impactful
In Dynamic turning, programmers can adjust the approach angle of the cutting tool in mid-operation. Also, tools with different cutting edges, suited to roughing, profiling and finishing, can mean performing multiple operations without tool changes.
Eccentric turning enables the machining of off-centre bores without specialty off-centre work-holding thus, eliminating the cost of custom fixturing and work-holding, while improving productivity, accuracy and setup time.
Bonus Features
While Multi-Tasking machines can expand your current capabilities, it can help you gain a foothold in gear cutting. Across South Africa’s manufacturing landscape, gear production plays a vital role in industries, such as mining, heavy equipment and the automotive aftermarket.
These sectors demand gears and splined shafts that meet tight tolerances. They must be produced efficiently, despite smaller batch sizes and growing part complexity. Implementing Gear cutting and the newer High Dynamic and unconventional Eccentric turning features will require use of digitaltwin simulation software and advanced Espirt Edge CAD/CAM software, to match the physical machine and its kinematics, so every tool index or collision risk that could exist is anticipated and addressed in the programming office.
Servicing an Ever-Increasing Pace
As these complex machines can complete nearly every part that crosses the shop floor, downtime could significantly hamper operations, most of it due to user error or lack of maintenance, however, thankfully Tongtai machines rarely see downtime. Even in these situations, our Intelligent Software assists with a troubleshooting feature that displays likely problem areas, such as Axis overloads and oil levels etc., while operators can quickly bring the machine back online, making a service call unnecessary.
To meet the production levels for newer jobs, it’s feasible to run two 12-hour shifts, one staffed and one unstaffed.
To prevent issues with outdated programs and help with traceability for high-requirement jobs, it is recommended to setup a programming department to ensure all changes to part programs are done in the right environment.
All these machine features will help expand your business significantly. By adding robotics, a custom ERP and continued investment in capable machines will help users grow even further.
We’re not just suppliers — we’re solution partners.
At PBS Machine Tools, we specialize in helping partners upgrade production, optimize capacity and access reliable equipment, not just by offering good pricing, but by delivering fit-for-purpose solutions, tailored to real production goals.
With our 35-year network of long-standing manufacturers and engineering teams, we support:
New and certified pre-owned machines
Custom-built lines for special parts or applications
Spare parts, tooling, installation and post-sale support
Government-level cooperation on industrial programs
We’d be glad to learn about your current focus, whether you’re exploring upgrades or future investments.
Special Note: I’d like to leave you with this:
From Defining to Preventing Errors
Four techniques to have in your toolbox for averting errors are
For more information please contact PBS Machine Tools – Tel: 011 914-3360.
MAPAL optimises machining for crankshafts and valve seats
Production figures for vehicles with combustion engines are in decline but are still very high, at around 75 million cars built per year. Ample reason for the industry to continue seeking ways to optimise series production. MAPAL is lending its support with new tool solutions for modern combustion and hybrid engines.
The automotive industry consistently prioritizes reducing cycle times and minimizing costs per part. With two examples from crankshaft manufacturing and valve seat machining, MAPAL shows how this can be achieved with the combination of processing steps and innovative tool technologies.
One-shot solution for drilling and deburring
The desire to save weight, and thus fuel, with less moving mass doesn’t stop at a classic component like the crankshaft. To remove material, a central relief bore runs through the entire component. Due to the shape of the crankshaft, the tool repeatedly enters and exits the material during machining. How many times depends on the number of cylinders in the engine.
This also determines the length of the drill. To process the entire crankshaft in one go, tools with lengths between 600 and 800 mm are required. MAPAL achieves this with a modular system. The drill body is a special replaceable head holder with TTS (Torque Transfer System) connection that guarantees an extremely stable joint. The MAPAL connection features optimal torque transmission and high changeover and radial run-out accuracies. For the desired tool length, the tool holder is screwed onto an extension. The TTD replaceable drill head at the tip is available in various geometric designs depending on machine performance.
One challenge in machining is the burrs that occur in the metal when the drill goes in and out. These burrs were previously removed in a separate machining step. MAPAL now offers a one-shot solution for simultaneous drilling and deburring. This is made possible by a modular combination tool in which an additional chamfer insert is integrated into the chamfer behind the drill head. This SNAP18 module is a miniaturised deburring system that has been individually designed by HEULE Precision Tools for the application. For reliable forward and reverse deburring, a small spring controls the insert and ensures the pre-drilled diameter is chamfered to the nearest tenth and is not damaged during deburring.
This tool solution saves the user a step and a space for a tool in the magazine. The cycle time is reduced.
Twelve inserts for valve seats
To reduce costs in the fine machining of valve seats, MAPAL has developed an innovative HNHX indexable insert. Like the predecessor model, the HNHX is also hexagonal, but twelve cutting edges can be inserted instead of six. The negative installation position enables this new indexable insert to be turned. A modified clamping star ensures maximum force closure and precise positioning in the insert seat. For the finishing of the valve seat ring, ultra-precise machining is required with regard to the specified tolerances and surface quality. With the HNHX, surface values of less than Ra 2.0 are achieved.
MAPAL recommends a combination tool for machining the valve seat and valve guide. In one machining step, the tool first machines the valve guide and then the valve seat with the HNHX indexable insert.
Further increase in efficiency possible for larger valve seat rings
Depending on the valve seat design, the HNHX indexable inserts can also be used much more than 12 times. Where possible from a construction perspective, such as for larger valve seat rings in lorries, these inserts can be used twice, meaning 24 cutting edges can be used. This is done by removing the cutting edge at the end of its tool life and re-using it in a different angular position. The cutting edges used are easy for the user to identify thanks to a corresponding coating. This enables simple repositioning in another insert seat and further processing using an yet unused area of the cutting edge
Doubling the number of cutting edges has a direct impact on the user’s production costs, the costs per part halve as a result. Tool life is also increased by the use of PcBN high-performance cutting materials developed within the MAPAL Group. Cutting materials are being customized to align with developments in the industry, enhancing the wear resistance of valve seat rings through the use of innovative materials. The robust clamping system results in maximum force closure and thus a homogeneous distribution of force in the insert seat.
Despite the clear trend towards e-mobility, the development of combustion engines continues. Not least for use in modern hybrid vehicles. MAPAL is at its customers’ sides as a technology partner and will contribute to further optimising their production in the years to come.
For more information, please contact Spectra Carbide Tooling Technology – Tel: 021 555 4144.
As part of a strategic move to streamline operations, strengthen regional alignment and support long-term growth, Specialised Exhibitions has transitioned to a new name, Montgomery Group Africa. This name change reflects the consolidation of Montgomery Group’s regional divisions across Africa under one unified management structure, creating a more agile, efficient, and future-focused organisation.
While the name is new, the company’s commitment to its people, partners and purpose remains unchanged. The transition marks a significant step forward in building a stronger, more connected presence across all regions in Africa.
“This transition is more than a name change, it’s a reflection of where we’re headed. By bringing our teams together under one identity, we’re building the clarity, strength and agility needed to grow with purpose across all regions,” says Gary Corin, who continues as Managing Director following the transition to Montgomery Group Africa.
“By simplifying structures and aligning leadership under one cohesive vision, Montgomery Group Africa will enhance collaboration, improve resource allocation and enable faster decision-making. This transformation will not only strengthen support for regional teams but also unlock greater opportunities for innovation, consistency and long-term growth across all markets,” adds Corin.
“This move marks a significant milestone in the company’s evolution , building a stronger foundation to better serve clients, empower teams and deliver lasting impact in the communities we operate in.”
Celebrating 130 years in 2025, Montgomery Group is the UK’s longest-running independent events organiser. A fifth-generation family-owned business, its portfolio includes over 50 events and co-locates across 15 countries. The global team is made up of over 150 passionate events professionals, united in their mission to deliver world-class exhibitions that provide meaningful platforms for industry connection, business generation and community engagement.
“Montgomery Group has proudly organised events across Africa since launching Specialised Exhibitions in South Africa in 1968,” notes Damion Angus, Group Managing Director and Chairman of Montgomery Group. “Since then, the Montgomery presence has expanded to include events in Botswana, Nigeria, Ghana, Kenya, Zambia, Libya and Zimbabwe, alongside our well-established portfolio of trade exhibitions throughout South Africa.”
“Bringing the full African events portfolio under Montgomery Group Africa supports the vision of an ambitious new phase of growth across the continent. We have strong, experienced teams in every region who are energised by the opportunities this consolidation unlocks.”
The move will see Propak Africa, Propak Cape, Propak West Africa and Propak East Africa leading as the largest packaging, plastics, print, food processing and labelling exhibitions across Africa. East Africa’s principal event for the security, fire and safety industry, Securexpo and its co-locates , will complement a growing portfolio including Securex Expo, A-OSH Expo, Facilities Management Expo and Fire Expo, hosted annually in Johannesburg and launching for the first time in Cape Town in October this year.
Gary Corin, Managing Director for South Africa, has additionally taken on the role of Managing Director for West Africa events. Angela Kinyua continues to lead as Managing Director of the East African events. Both are operating within the unified Montgomery Group Africa structure.
“Our locally based marketing team is leading the rollout of the Montgomery Group Africa brand across the African region,” says Corin. “This includes overseeing all marketing communications and collateral development. They are working closely with our East and West African marketing teams, drawing on their valuable regional insight and experience to ensure a consistent and impactful brand presence across all markets.”
This change will not impact day-to-day operations. The registered business entities in each region, including South, East and West Africa, remain unchanged, and all current invoicing and banking details will continue as usual.
The name change has taken effect from 01 September 2025.
Innovative coating makes the brake disks fit for strict Euro 7 standard
Jannik Röttger can still remember the first attempt at grinding a hard-coated brake disk: “The grinding disk broke in the machine”, he adds. The new, extremely hard material was considered revolutionary in the industry. Röttger is now Head of Grinding Technology at the machine tool manufacturer Emag in Salach, Baden-Württemberg. And the brake disks, which were tested at that time in the machine tool laboratory of RWTH Aachen, are close to a major breakthrough. They meet the strict requirements of the Euro7 standard and from 2026 should ensure that the hazardous fine dust pollution in traffic areas is reduced considerably. Approximately 100 million brake disks are produced in Europe every year.
Up to 90 percent less fine dust when braking
The development of the brake disk, with which the arising particle quantities during braking can be reduced by up to 90 percent, was a major accomplishment for the industry. A hard coating was preferred early on because it was considered particularly efficient, corrosion-resistant and durable. One flaw: its price. Fans of sports cars and SUVs in the luxury class might be prepared to pay up to five-figures for a particularly efficient brake system. But this does not hold true for the majority of motorists. An affordable variant had to be found.
The Fraunhofer IKTS (Institute for Ceramic Technologies and Systems) in Dresden, among others, focused on the development. As stated, for the new coating a powder of carbide, a mixture of carbon and a metal, is mixed using a special nozzle system and applied to the rotating brake disk with a laser. This method and the powder materials used allow very thin layer thicknesses to be achieved. It is essential that the expensive material carbide is used very sparingly. The subsequent grinding process is about achieving the required surface properties.
Digital networking is a must
Suitable machine and tool technology is now available, corresponding production lines are entering the halls of the automotive industry. Comprehensive test runs, during which thousands of brake disks were machined, led to the desired results. But that alone was not enough. For economic production, optimization potential across all technologies was sought in the entire manufacturing process from the casting of the blank, to turning, laser coating and grinding through to the resulting function properties in the vehicle. Attention was also paid to how the manufacturing process can be modified in a targeted manner and customized depending on the raw material and individual requirements. What’s more: “Already in the early phase of the development our customers wanted to have everything documented”, reports Mario Preis, Head of Technology & Corporate Development at DVS Technology Group, Dietzenbach, who specializes in surface treatment. The brake disk is always a safety-critical component subject to high quality requirements. The companies are also required to document everything with regard to the EU CSRD (Corporate Sustainability Reporting Directive) on comprehensive sustainability reporting. For Mario Preis, there is no alternative to digital networking of the process chain. Only digital networking enables the system view to repeatedly adapt manufacturing processes to new requirements and to comply with documentation duties reliably and at the same time economically.
Service as a new business model
In order to facilitate entry into data-driven production, many machine tools are already equipped with extensive sensor and monitoring systems ex works. The machine builders also provide suitable infrastructure and software components so that data can be captured, analysed, and visualized across the entire process chain using different technologies. The VDW (Verein Deutscher Werkzeugmaschinenfabriken) in Frankfurt/Main wants to show how this works at its trade fair EMO Hanover, which takes place from 22 – 26 September. There the interest groups of machine tool manufacturers will bring together companies from almost all continents and present worldwide innovations in the area of production. And it is no longer just about innovative machines.
Emag, for example, will also present their solutions in North Germany. Because Jannik Röttger is convinced that competency in complex production contexts will be increasingly decisive for industry. “The process chain will become the business model”, he says, as is reflected using the example of the hard-coated brake disk. However, he still believes real tests cannot be completely eliminated in the digital world. At Emag at least they will be included once again for hard-coated brake disks – this time for commercial and rail vehicles.
How artificial intelligence is revolutionizing production
Industrial manufacturing is undergoing a change for the ages. Artificial intelligence (AI) is finding its way into machine tools and is not only changing production processes, but also the maintenance of machines. AI is becoming the control centre for efficient, sustainable and competitive production. In times of skills shortages and international competitive pressure, it is far more than just a technological gimmick: it is becoming a survival strategy. At the EMO Hannover 2025, the world’s leading trade fair for production technology, you will be able to see how artificial intelligence is revolutionizing industrial production from September 22 to 26.
AI in machine tools means much more than just automation. It enables machines to learn from data, make decisions and optimize processes. Sensor technology, data analysis, machine learning and intelligent assistance systems are used for this purpose – both at the control level and in interaction with people.
Increasing the individual potential of AI
Prof. Philipp Klimant Fraunhofer Institute for Machine Tools and Forming Technology (IWU).
There are many possible applications for manufacturing companies: “Typical examples would be the prediction of process properties in real-time operation for inline quality control and the monitoring of processes and their properties,” says Prof. Philipp Klimant, Head of Business Unit Process Digitization and Manufacturing Automation at the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) in Chemnitz. “The advantage over traditional approaches is the ability to include a particularly large number of parameters in the monitoring process,” highlights Klimant.
However, there are also numerous other fields of application, such as AI assistance models for training and artificial intelligence to support maintenance. The Fraunhofer IWU, which specializes in the production-related adaptations of traditional and modern machine learning methods, is headed by the trio of Martin Dix, Welf-Guntram Drossel and Steffen Ihlenfeldt. All three are members of the WGP (Wissenschaftliche Gesellschaft für Produktionstechnik/German Academic Association for Production Technology), an association of leading German professors in the field of production science. As of January, the WGP has consolidated the ProKI initiative, which was originally funded by the BMBF, under its umbrella and has since been offering highly practical expertise and demonstrators, especially to small and medium-sized companies that want to find out about the potential of AI for their individual situation and/or are looking for support.
Great leverage for efficiency gains
The IWU researcher’s tip is to ask the following question at the very beginning: How large are the efficiency gains that are actually possible through AI in my production process? “The question of what efficiency gains are possible cannot be answered universally without further analysis,” says Klimant. The potential is heavily dependent on the actual process and the associated optimization possibilities. “In the field of plastics processing, injection moulding for example, reject rates of 20 to 30 percent can occur in rare cases.” This represents a major lever for efficiency gains with AI. It can also be useful for processes that are already running with a high level of stability, for example in the area of predictive maintenance and to achieve longer service lives of tools.
According to Klimant, artificial intelligence can also make an important contribution to alleviating the shortage of skilled workers. “We store knowledge implicitly in AI. This knowledge can be used to train new employees, especially when older colleagues retire and important knowledge leaves the company,” explains the scientist, who has also been Professor of Virtual Technologies at Mittweida University of Applied Sciences in Saxony since 2023. “This repository of AI knowledge also offers new opportunities for automation, not least for automated quality control,” says Klimant.
The researcher defines artificial intelligence as follows: “When we talk about AI, we usually mean machine learning as a subgroup of AI. This is able to learn independently from training data. It is an empirical process that learns correlations without us knowing the analytical correlations. Simply put, we learn from experience.” AI is used to optimize the process parameters in production and feed them back into the process controller via an automated control system. “Artificial intelligence is like a black box, input values go in and forecasts come out,” says Klimant. “One example of this would be a forming process where we measure an acoustic signal and then the AI tells us whether or not the process was successful.” Ultimately, it is a digital system that can be connected to control systems via existing interfaces. This allows AI to influence control algorithms at various points.
High computing power for image processing
In order for artificial intelligence to be used successfully in production, hardware with very high computing power is sometimes required. “First of all, a distinction must be made between the training phase and the utilization phase (inference). The training phase is always more computationally intensive, but is carried out offline. In the utilization phase, edge devices are often sufficient for classic methods such as the support vector machine,” says Klimant. The situation is different when it comes to the topic of image processing. These AI models require more computing power, both in the training phase and in the utilization phase. “The application cycle also plays a decisive role here,” explains the researcher. “If I need a result every five seconds, for example, I will need more computing power compared to a cycle time of 30 seconds.” The evaluation of language models represents an exception here. These require powerful hardware, from high-performance consumer graphics cards through to special AI cards.
Self-learning machine tools enabling autonomous production
Jonas Gillmann, Chief Technology Officer (CTO).
Self-learning machine tools are made possible by AI. Milling machine manufacturer and EMO exhibitor Datron AG from Ober-Ramstadt near Darmstadt makes use of this innovation, in which the machine draws on learned knowledge and adapts the production process. The aim is to develop Datron milling machines into adaptive production cells that automatically adjust to component requirements and environmental conditions. “This not only reduces set-up and machining times, but also increases process stability – a decisive step towards autonomous production,” says Jonas Gillmann, Chief Technology Officer (CTO) of the publicly listed mechanical engineering company.
AI is thus shifting the focus away from rigid programming towards assisted, self-learning and adaptive production. “Machines are becoming partners in the manufacturing process, which adapt to humans – not the other way around. In mechanical engineering, this is no longer a vision, but is increasingly becoming a reality,” says Gillmann. As he explains, AI in production offers high levels of efficiency gains: “In CNC production with Datron machines, it can reduce set-up times by up to 60 percent, significantly reduce the amount of rejects and extend the service life of tools – while at the same time increasing process reliability.”
Intuitive guidance through the milling process
One particularly exciting advance is the link with the “Datron next” control software, says Gillmann. This guides even inexperienced operators intuitively through the milling process and automatically recognizes workpieces. “This means that even employees who are not specialized in the technology can perform milling productively – a clear advantage in view of the shortage of skilled workers,” says the Datron Chief Technology Officer, who started his career as an industrial mechatronics technician at the milling machine manufacturer from Hesse. According to Gillmann, AI will in future also allow predictive maintenance to be carried out in order to prevent failures before they occur. “This will make the milling process more efficient, more robust and much more flexible in terms of the personnel required.”
Artificial intelligence in machine tools can also help to meet the increasing demand for customer-specific products with small batch sizes. “AI makes the production of small batch sizes economical: With the Datron next control software, workpieces are recognized automatically – without complex programming,” says Gillmann. “This eliminates the need for long set-up times, and individual parts can also be manufactured quickly, efficiently and to a high level of quality – which is ideal for customized products.”
Less programming, more process responsibility
Self-learning machine tools are also changing the job description of the user: “Less programming, more process responsibility,” is how the Datron CTO sums up the change. Employees are becoming process designers who ensure quality and optimize processes. “This lowers the barrier to entry and human expertise is supplemented – not replaced – by smart assistance.”
Industry 4.0 under its own control: Maschinenfabrik Heller has been implementing the EMO 2017 motto "Connecting systems for intelligent production" with its own networked production lines for years.
By Nikolaus Fecht, Gelsenkirchen, Germany
In June 1975, almost all of Paris is dreaming of love – à l’électronique. As the new, electronically controlled RER high-speed train begins its journey, the Centre Pompidou with color-coded pipes and electronic building technology is being built in the middle of the city. At the same time, the international machine tool industry celebrates the premiere of the “Exposition Mondiale de la Machine-Outil” – EMO for short – at the Parc des Expositions de la Porte de Versailles. The common denominator of the three events is that they herald the global dawn of a new era in which electronics are gradually taking over. A look back by technology journalist and contemporary witness Nikolaus Fecht.
Farewell, EWA – that’s the word in Paris in 1975 and two years later in Hanover. EMO is the successor to the “European Machine Tool Exhibition”, which has been held alternately in Belgium, Italy, France and Germany since 1951. The continental industry show will become an international event, to which the European machine tool association Cecimo invites visitors alternately to Milan, Paris and Hanover.
Numerical control: cam disk and camshaft passé
For the first time, the European machine tool industry will be showcasing itself at a trade fair with international appeal throughout. One impulse from the USA in particular caused a stir in the mid-1970s: numerical control (NC). Cam disks, camshafts and mechanical copying devices have been replaced by programmable control systems that allow motion sequences to be flexibly defined via software for the first time. But this is just the beginning, oracles a German trade journal at the time: “The first machine tool world congress concludes with a discussion on the future development of machine tool control in conjunction with the use of computers.” But it’s not that far yet, punched tape still dominates the scene – the classic storage medium for numerically controlled machines.
German EMO premiere – In 1977 – two years after Paris – the machine tool industry showcases itself for the first time on a global scale in Hanover.Nikolaus Fecht
I learned about the next step towards CNC – “Computerized Numerical Control” – as a working student in the mid-1970s in Thyssen’s large training workshop in Kassel. However, the handling of this technology needs to be learned first: “Hands off, this is not for beginners!” a master craftsman tells the budding electrical engineer as he curiously inspects his first CNC machine: A CNC machine tool over three meters high – equipped with an early Siemens control system. The student looks at a magnetic tape input system that glows amber.
Advance from Japan – Every fourth lathe has a CNC system
No wonder I’m fascinated by the newcomer – after all, CNC is still a technical exception in the mid-1970s. According to the National Bureau of Economic Research, Cambridge (USA), less than five percent of machines in the United States are CNC-controlled, and only around two percent in the Federal Republic of Germany. Only Japan is much further ahead: In 1975, one in four lathes exported already had a CNC system – and the trend is rising sharply.
The production experts look with enthusiasm at computer solutions from the Far East or the USA, but for a long time they are sceptical: I am one of them. During my first visit to EMO in Milan in 1987, as a trade editor I get to know high-tech from the Far East: Mitsubishi presents a CNC system that supposedly works five times faster than conventional 16-bit systems and even optimizes machining automatically thanks to artificial intelligence. For me as an engineer journalist, a new era is beginning, which I refer to in the trade press as “CIMsalabim” – a tongue-in-cheek allusion to “Computer Integrated Manufacturing” (CIM), where robots, machine tools, assembly lines, measuring stations and computers merge to form a computer-integrated factory.
The digital trend will soon be followed by green issues – initially ridiculed, then promoted and finally demanded. High-speed machining (HSC) played a key role. The process enables extremely fast machining with high surface quality – and with very little or no cooling lubricants. At EMO Hanover 2001, Getrag Ford Transmission GmbH demonstrates how HSC and minimum quantity lubrication can be combined to conserve resources. During an on-site report for the EMO press service, I learn: “One glass of Kölsch beer is enough to process 90 gearbox housings” – previously it was 220 litres of emulsion. The VDW also recognizes the potential early on. HSC became a promoted key technology, flanked by eco projects and the Blue Competence initiative. At EMO 2011 at the latest, it becomes clear that energy efficiency is no longer a sideshow.
Dry machining with HSC: High-speed machining entirely without cooling lubricant – what started out as an experiment at the beginning of the 21st century has become a symbol of resource-saving manufacturing.
Industry 4.0 – from label to evolution
A few years later, a new guiding principle provides further impetus: Industry 4.0 stands for the idea of networking production systems using powerful computers, sensors and interfaces in such a way that they can be controlled and analysed in real time – ideally even by cell phone. “A smartphone for production”, a developer says in a tongue-in-cheek manner at EMO Hanover in 2017.
However, the first step is to link systems intelligently with one another. Under the guiding theme of “Connecting systems for intelligent production”, EMO is sending out a clear signal for digital networking in production technology. In 2019, umati (universal machine technology interface) – the global initiative for open communication interfaces for the mechanical engineering industry and its customers based on OPC UA information models, initiated by the VDW – celebrates its premiere in Hanover. Since then, umati has continued to develop: Today, under the umbrella of VDW and VDMA, the international community guarantees standardized information models for numerous applications, offers a platform for exchanging experiences, creates visibility on the market and enables the practical demonstration of added value. Open interfaces now exist not only for machine tools, but also for components, software solutions and many other manufacturing technologies – a decisive contribution to the smooth cooperation of a wide variety of systems in networked manufacturing.
The year 2020 becomes a test: Within a short space of time, virtual communication becomes established – a replacement for coronavirus-related contact restrictions. Companies are switching to remote maintenance, digital customer formats and flexible logistics. Further adjustments follow in 2022 with the loss of Russian gas supplies – from energy efficiency to the realignment of global supply chains. Industry 4.0 is becoming a living practice. Virtual services such as remote maintenance, remote diagnostics and online training are replacing on-site deployment in many places. Digital tools support customer contact, while cloud-based platforms enable training and support regardless of time and place.
Industry 4.0 under its own control: Maschinenfabrik Heller has been implementing the EMO 2017 motto “Connecting systems for intelligent production” with its own networked production lines for years.
Efficient communication despite coronavirus contact restrictions
Contactless communication works efficiently, I observe while researching for a text: “Digitalization shows its strength above all in combination with online communication. We are talking about troubleshooting, teleservice and remote diagnostics, the flexibility of which many companies have come to appreciate in times of crisis.” The pandemic is therefore becoming a catalyst for digitalization – in service and in interaction. This experience still shapes our service structures today. Some people wonder whether physical trade fairs are still necessary at all – after all, virtual communication works surprisingly well these days.
Virtual communication is here to stay – but the next technological leap is already in the pipeline. Shortly after the digitalization push caused by the pandemic, an old acquaintance is back in the spotlight: artificial intelligence. While Asia and America are already investing, Professor Jörg Krüger from the Fraunhofer Institute for Production Systems and Design Technology IPK, Berlin, warns: “Without AI, soon a knockout (KO)” – and advises linking the domain knowledge of workers with neural networks. Data is the “digital gold dust” of production, from which new business models can emerge. This claim will become tangible at EMO 2023: Trumpf presents an AI assistance system for the automatic sorting of sheet metal parts, J.G. Weisser shows predictive maintenance based on learning algorithms. Mapal, Ceratizit and the Fraunhofer IPT also demonstrate how AI optimizes manufacturing processes, reduces testing times and makes machines more intelligent. AI is on its way from buzzword to standard – visible at more and more stands at EMO.
And yet EMO 2023 in particular showed that networking does not replace personal exchange, but enriches it. Under the claim “Innovate Manufacturing.”, the VDW attracted over 90,000 experts from all over the world to Hanover – around half of them from abroad. The trade fair impressively demonstrated that digitalization promotes dialog. In Hanover, I have come full circle, having stood at my first CNC machine 50 years ago as a curious student worker – and now reviewing half a century of EMO experience as a technology reporter. My exciting question: What happens next?
My research shows that EMO 2025 will once again focus on digitalization, automation and sustainability – complemented by new AI applications. Together with Siemens, DMG MORI is showcasing an end-to-end digital twin. Sandvik Coromant launches smart tool holders with real-time monitoring. Supfina presents a new machine concept for surface finishing, and VibroCut introduces ultrasonic support for machining. At the same time, MAPAL reminds us that classic tool solutions still have their place. VDW Chairman Franz-Xaver Bernhard puts it in a nutshell: “The future of production is created where innovation meets experience – and that is precisely the strength of EMO.”
