Industry 4.0 : Manufacturing's Next Move

Industry 4.0 is influe­ncing the process chain in two ways: firstly, in terms of technology and engi-neering, and secondly in terms of the data flowing along with it. When both of these interact to optimum effect, a textbook example for Industry 4.0 is obtained.

“This applies in regard to qu­ality and disturbance variables, but also and increasingly to predictable parameters such as tool paths and tool lifetimes, achievable surface qualities, and for maintenance intervals for machines and lines,” explains Prof Dr Frank Barthelmä, Executive Director and Institute Manager, GFE – Gesellschaft für Fertigungstechnik und Entwicklung Schmalkalden e.V.

Ideally, users receive all important information on the entire spectrum of process-related factors. What is more, all data available can now be recorded and evaluated in real-time, and control loops created, so as to upgrade the efficiency of the processes and the quality of the products involved, thanks to more transparent metal-cutting.

Role of tool sensors and actuators

About a decade ago, there was an ongoing debate on whether or when a tool can be classed as intelligent. Today, within the context of Industry 4.0, intelligent holistic solutions are talked about in which tool sensors and actuators play an important role. “That correctly makes them ‘state-of-the-art’,” stresses Dr Barthelmä. “Not only in terms of using increasingly miniaturized and more energy-efficient sensors or actuators in the tool itself, but also with a view to their utilization in the overall system comprising the tool, the machine and its control system, and the application concerned.”

Evaluating multiple data

Many potential users of intelligent solutions, especially SMEs, are sometimes unable to assess what data they actually need in order to render their technology/IT fit for purpose, and to generate from these new production lines when needed. This extends to new business models that may prove necessary. Universities and large corporations are already well advanced in this respect, whereas many of the small and mid-tier companies are still in the exploratory phase. For meaningful analysis, moreover, a comprehensive data history is required, in order to correlate it with new key statistics.

According to Dr Barthelmä, we need an even more collabora-tion between the academic and business communities when it comes to generating new ideas, models and new solutions. Idea­lly, there should be more joint projects involving partners from the academic community and the industrial sector representing a highly disparate range of scientific disciplines, which can elucidate these questions with the aid oflive demonstrators.

Collaboration between software analysts and metal-cutting experts

This will work if the SMEs get involved at an early stage. The networks supported by the Federal Ministry of Economic Affairs, for instance, have proved worthwhile in this context. For example, the GFE is currently a partner in the SME 4.0 Competence Centre of the Ilmenau University of Applied Science, and in a model factory is addressing problems encountered with data generation and data transfer in connection with metal-cutting – for transfer especially in SMEs. The question involved here is this: how can a control loop in the machine be utilised so as to ensure that quality, efficiency and productivity can serve as controlling target variables?

Looking into the future: at the EMO Hannover, the GFE will be showcasing the current status of digital matters as exemplified by the EU project entitled “Dyna-Tool – Enhanced Efficiency in Meta-Cutting Applications”

Analysing metal-cutting parameters

In the case of new materials, it is becoming progressively more important to close the loop in the control circuits with the aid of analytics. “There is still quite a bit of work to be done on the path to purposeful evaluation. There is room for improvement, too, in the transparency of the results. A pre-competition platform should be accessible to manufacturers and users alike,” opines Dr Barthelmä. A data pool should also be in place so that everyone does not  have to keep on re-inventing the wheel. It is worthwhile for a manufacturer if users learn which of his tools are best suited for efficiently machining new materials. GFE is contributing towards this with the SME 4.0 Competence Centre.

Current highlight from the work

The EU’s “Dyna-Tool – Enhanced Efficiency in Metal-
Cutting Applications” project, supported by the German Engineering Federation’s Pre­cision Tool Association and the research institute Forschungskuratorium Maschinenbau e.V., is tasked with investigating how vibration-stable metal-cutting processes can be designed using sensor technology in the tools and the tool holders.

For this purpose, GFE has within the framework of the project developed a sensor-integrated tool for hard machining, which, thanks to direct integration in the machine’s control, enables the process to be controlled almost in real-time.

The Dyna-Tool consortium has succeeded in putting more transparency into the metal-cutting process, so that it can be kept within defined limits for low vibrations, but at the same time is able to exploit
its performative potentials to the full.

GFE is also currently examining the integration of high-resolution metrological devices in the tool, including an interface with the control system, so as to use this to create a real-time control loop. Anyone interested can learn more about this and other projects at the EMO Hannover and its forum entitled “Innovative Solutions for Industry 4.0” hosted by the German Engineering Federation’s Precision Tool Association.

I4.0’s influence on metalcutting

Dr Niklas Kramer, Director Product and Industry Segment Management, Sales Area Central Europe, Sandvik Coromant, gives three reasons why Industry 4.0 is influencing the world of metal-cutting: “Firstly, it focuses attention on the value-adding processes involved, since resource-gobbling activities around the actual production process can hopefully be automated to an increasing extent using I4.0.”

“Secondly, metal-cutting is a highly empirically-based field. The more we succeed in gaining insights either on the basis
of data or by means of
statistical methods, the better we shall be able to design and optimise metal-cutting processes,” he adds.

Lastly, the sector is nowadays exhibiting a major gap between metal-cutting research and
practical applications. A modest plus in terms of system intelligence would be helpful here, whether it is an I4.0 machine or a process monitoring system, for example, enabling better decisions to be made faster, and deviations to be detected earlier.

Transferring ideas: digital transformation is a difficult undertaking, especially for small and midtier companies. It may prove helpful for them to tackle the issue jointly in networks, as is the case here at the GFE in Schmalkalden.

Cloud instead of a physical tool ID

Similar developments are also taking shape in Tübingen at Hartmetall-Werkzeugfabrik Paul Horn GmbH. “In future, tool data will be acquired over the entire life-cycle,” says Markus Kannwischer, Head of Engineering & Member of the Board. “This applies particularly to tools that are re-sharpened or retrofitted.” In these cases, all relevant geometric data shall then be transferred to
the cloud; a physical tool ID is thus superfluous.

The tools are changing too: there is an accelerating trend towards sensor technology, that in the tool, in the vicinity of the blade, acquires, processes and transmits measured values. From these data, algorithms are then tasked with drawing conclusions on machining parameters and regulating the control systems accordingly. To quote Kannwischer: “Ideally, it will no longer be necessary to enter feed and setting values in the control system; rather, the tool itself will continuously send information on its condition and the control system will take appro­-
priate action.”

Real trials are not passé

But the virtual future is not rendering real trials superfluous. For example, the machinability of new materials will still have to be determined by actual trials, despite simulations and analytical methods. However, the number of trials can be restricted because a better data basis is available. Generally, though, a solid basis of data will allow a tighter process window when running in workpieces involving familiar materials.

Networking at EMO

Acquiring the metal-cutting parameters also facilitates mac­hining – e.g. with a view to new materials. “Often they are not very amenable to metal-cutting because the empirical knowledge and the research results are not available, or we first of all have to try out the old solutions before we develop any new ones,” explains Dr Kramer. “I believe that if we could bring together the global first tentative steps involving a new material at a single location, we would have significantly steeper learning curves. One aspect we’re generally focusing on in the context of Industry 4.0 is rapid response based on simply edited data.”

On this subject, Sandvik Coromant will be showcasing design enhancements of the CoroPlus platform at the EMO Hannover 2017, which offers its users networked solutions for increased process dependability and savings in terms of design and planning. To quote
Dr Kramer: “Since 2016, quite a bit has been firmed up and design-enhanced, so we are hoping that this time, like at the last fair, we will once again be able to elicit an enthusiastic response.”

Meanwhile, Dr Barthelmä, with his primary interest in the examples of best practices, will be seen talking to
other advocates of these ideas on more transparency at the event: “I shall thus be attempting at the EMO Hannover, within the context of my networking activities, to gain additional co-campaigners for more openness and transp­arency in the sector.”

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