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Hybrid is “in”: printing and metal-cutting in a single pass
METAV 2016 to showcase additive manufacturing in all its facets
Frankfurt am Main, 22 October 2015 – In parallel to the METAV 2016, at
the Düsseldorf Exhibition Centre on 24 and 25 February 2016, a specialists’ conference called “Inside 3D Printing” will be held. It will cover the
conference’s entire spectrum of additive manufacturing with metals
and plastic components. The watchword is no longer printing instead of
metal-cutting, but increasingly printing and metal-cutting. Hybrid machines are on the advance: they are extending field-proven metalcutting techniques to include the multifaceted options offered by additive manufacturing in a single workspace.
The integration of additive manufacturing processes into the metalcutting operation, in the estimation of Dr. Eric Klemp, Commercial E Director of the Direct Manufacturing Research Centre (DMRC) at Paderborn University, and responsible for the programme of the “Inside 3D
Printing” conference at the METAV 2016, offers a series of options and
additional benefits for the user. “By combining material build-up and
removal in a single machine, functions can be integrated in a way
hitherto impossible. For instance, different kinds of material can be used
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in a single manufacturing process. One additional benefit is that the
process incorporates the long years of expertise accumulated by the
machine tool manufacturers.” The 3D expert sees further advantages in
the options available for mass production and standardisation, plus the
aspects of accuracy, reproducibility, production of undercuts, utilising
freedom of form, and material savings. Not least, two processes are
being merged with each other, which helps to synergise the advantages of both.
Integrating the core competence of additive manufacturing is by no
means a trivial matter. In terms of technology, it means another rethink,
since fit-for-manufacturing design will in future be accorded even more
attention. For this purpose, what’s needed are “smart people who are
willing and able to combine the two,” to quote Eric Klemp.
From the METAV 2016, the expert is expecting a fruitful exchange of
new and views with the machinery manufacturers, further stimulating
input and detailed statements, initial components, and above all a
chance to see corresponding machines live in action.
METAV 2016 as a platform for innovative minds
Rainer Gebhardt, Project Manager of the Additive Manufacturing
Working Group in the German Engineering Federation (VDMA), sees the
advantages of hybrid machines not least in the scope they offer for
creative design and machining in a single set-up. All this benefits accuracy levels. It’s generally accepted that most deposited contours have
to be reworked. This can be very flexibly implemented in the hybrid
machine.
Hybrid signifies in Rainer Gebhardt’s estimation “sensible distribution of
additive and subtractive machining. Additive wherever the design demands it, and subtractive wherever the semi-finished product and the
volume of the component concerned render a metal-cutting process
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the sensible choice. Building up large components in an entirely additive process, however, makes sense only if it’s essential - otherwise the
combination is better, of course,” adds Rainer Gebhardt.
According to Rainer Gebhardt, the process is an obvious choice for
repair jobs in particular. As with all additive manufacturing processes,
however, the challenge consists of identifying a suitable application
case in the overall environment. To quote Rainer Gebhardt: “You also
have to look at the different hybrid processes available – and the costs,
naturally. Hybrid also means, of course, that one of the two processes is
standing still.”
Some users, says the VDMA’s expert, are accordingly taking a close
look at hybrid production. Not in one machine, but certainly the combination of semi-finished product and subtractive manufacturing plus
additive manufacturing. This is “precisely what’s exciting about the new
technology – in a huge variety of different sectors, innovative minds
have taken note, and are trialling solutions. We in the Working Group at
the German Engineering Federation bring together precisely this sort of
people – from the user sectors and from the technology vendors. This
encourages development work on both sides. There’s no shortage of
potential – the new processes frequently offer crucial competitive options. The METAV 2016 is an ideal platform for this.”
Another step towards a shorter process chain
The integration of additive manufacturing processes into a complete
machine is explained by Reinhard Koll, Head of Applications Engineering at WFL Millturn Technologies GmbH & Co. KG in Linz, Austria. To
quote Reinhart Koll: “We are aiming to integrate a laser without restricting the flexibility of the basic machine.” Special attention is paid here to
automatic replacement of the laser unit. This is conditional upon enabling the technology of additive manufacturing to be integrated into
the machine without manual interventions. Laser technology comple-
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ments the machines’ already-existing machining options, so as to shorten and simplify the process chain and thus the throughput time as well.
Worksteps that hitherto necessitated unclamping and external processes can now be implemented on a single machine. According to
Reinhart Koll, this not only produces advantages in terms of throughput
time and process control, but also helps to significantly improve component quality and save make-ready costs.
The approach to a process combination of this kind from the viewpoint
of the machinery manufacturer, who in most cases possesses competence in metal-cutting, is described by applications engineer Reinhard
Koll as follows: “The option of welding, hardening, and material deposition was best imaged by an application for powder laser deposition
welding. This technology contains all the requisite elements. The multifarious materials that can be machined using this process, in conjunction with the high deposition rates, constitute optimum preconditions for
a broad spectrum of applications.”
The additional benefit for the user is the opportunity to save worksteps.
Further technologies, like welding, hardening and coating, are available for specialised machining jobs in addition to the basic technologies
in the machine. Manufacture of complex geometries that are difficult
or even impossible to create using conventional processes is now within
reach. In the case of geometries that protrude from the workpiece,
overdimensioned blanks can be dispensed with. This saves machining
time, and enables the user to continue working without reclamping
with metal-cutting processes. In the case of expensive or difficult-tomachine materials in particular, this aspect should not be underestimated. To quote Reinhard Koll: “Besides creating geometries, the coating of functional surfaces with corrosion-proofing or anti-wear layers is
an additional benefit that is of interest to many users.”
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Typical application categories include coating worms, rotors, screw
spindles, hardening bearings, toothing systems, sealing ring seats or repairing expensive damaged workpieces. Currently, adds Reinhard Koll,
“some specific application options are being analysed with interested
parties. However, it’s not easy to estimate in which sectors this technology will become established in the medium and long term”. Many design engineers and manufacturing firms have had their eyes opened to
new and hitherto unknown options. “There’s a thinking process ongoing
here, which will substantially influence the future potential of this technology,” to quote the WFL expert. The Additive Manufacturing Area at
the METAV 2016 will also be making a contribution here.
Author: Walter Frick, specialist journalist from Weikersheim
Number of characters including blanks: 7799
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Background
METAV 2016 in Düsseldorf
The METAV 2016 – the 19th International Exhibition for Metalworking Technologies – will be held in
Düsseldorf from 23 to 27 February. It showcases the entire spectrum of production technology. The
principal focuses are machine tools, production systems, high-precision tools, automated material
flows, computer technology, industrial electronics, and accessories, complemented by the new
themes of Moulding, Medical, Additive Manufacturing and Quality, which are now permanently
anchored in what are called “areas” with their own nomenclature in the METAV’s exhibition programme. The METAV’s target group for visitors includes all branches of industry that work metal,
particularly machinery and plant manufacturers, the automotive industry and its component suppliers, aerospace, the electrical engineering industry, energy and medical technologies, tool and
mould-making, plus metalworking and the craft sector.
Further information under www.metav.de
Inside 3D Printing Conference 2016
The Inside 3D Printing conference will be held on 24 and 25 February 2016 at the Düsseldorf Exhibition Centre together with the METAV. It offers a full conference agenda on the topic of additive
manufacturing with metals and plastic components. The sectoral focuses are aviation, automaking, the tool industry and medical technology. Thanks to the alliance with the METAV, the organiser
Meckler Media aims to create synergies for the conferees, and to significantly increase the number of visitors to the accompanying trade fair. To quote Dr.-Ing. Eric Klemp, who’s responsible for
the programme of the Inside 3D Printing Conference: “Visitors to the Inside 3D Printing want to
explore the limits of the currently available methods for 3D printing, in both technical and commercial terms.”
Further information under http://inside3dprinting.de/de
DMRC - Direct Manufacturing Research Center
Das Direct Manufacturing Research Center (DMRC) was set up in 2008 by Boeing, EOS Electro
Optical Systems, Evonik Industries and SLM Solutions GmbH, and by Paderborn University. The
DMRC is a research centre, which taps into the expertise of the partners involved from the industrial sector and the academic community in order to integrate additive manufacturing processes as
production processes ready for series production. The specific goals of the DMRC are: to progress
crucial technical advances for using direct manufacturing in series production operations, to introduce and transfer AM technologies into new and existing companies, to promote the corresponding paradigm shift from product-referenced design to function-referenced design, to training and skill a new generation of engineers, to conduct independent market studies and to evaluate methods and processes, and to create scenario projections for the future of DM.
Further information under: www.dmrc.de
Additive Manufacturing Working Group in the German Engineering Federation (VDMA)
The aft Additive Manufacturing Working Group brings together all parties involved along the value
creation chain involved in industrial-scale additive manufacturing: both researchers and material
suppliers, plus equipment manufacturers and service providers, all the way through to users from
the plant and machinery manufacturing sector. Currently, 90 members of the Additive Manufacturing Working Group are benefiting primarily from know-how transfer. The main thematic focus of
their work is on automation and machinery acceptance-testing for additive manufacturing.
Further information under: http://am.vdma.org
WFL Millturn Technologies GmbH & Co. KG
Why have different machines when one of them can do everything? WFL Millturn Technologies
GmbH & Co. KG in Linz, Austria, is a leading vendor in the field of complete machining. WFL is the
only manufacturer in the world to concentrate entirely on producing multifunctional turningdrilling-milling centres. The “Millturn” brandname nowadays in many high-tech companies epitomises the paramount manufacturing tool for producing complex components to maximised
standards of precision. The centres’ modularised construction, plus individually customised solutions, guarantee they are perfectly matched to the manufacturing job involved. In addition, WFL
offers customised software solutions for each machining task: for simple programming of complex
machining jobs, for 3D simulation and for effective collision avoidance.
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Further information under: www.wfl.at
Your contact persons
VDW (German Machine Tool Builder’s Association)
Sylke Becker
Press and Public Relations
Corneliusstrasse 4
60325 Frankfurt am Main
Germany
Tel. +49 69 756081-33
s.becker@vdw.de
www.vdw.de
DMRC – Direct Manufacturing Research Center
Dr.-Ing. Eric Klemp
Geschäftsführer / Commercial Director
Mersinweg 3 – Building W
33098 Paderborn
Germany
Tel. +49 5251 605415
eric.klemp@dmrc.de
www.dmrc.de
VDMA Additive Manufacturing working Group
Rainer Gebhardt
Project Management
Lyoner Strasse 18
60528 Frankfurt am Main
Germany
Tel. +49 69 6603-1902
rainer.gebhardt@vdma.org
http://am.vdma.org
www.vdma.org
WFL Millturn Technologies GmbH & Co. KG
Mag. Sabine Steinkellner
Marketing
Wahringerstr. 36
4030 Linz
Austria
Tel. +43 732 6913-74612
sste@wfl.at
www.wfl.at
Editorial Office Frick
Walter Frick
Hölderlinstr. 2
97990 Weikersheim
Germany
Tel. +49 7934 990021
redaktionsbuero@walter-frick.com
You will find texts and pictures about the METAV 2016 on the internet under www.metav.de in the
Press Service. You can also visit the METAV through our social media channels
http://twitter.com/METAVonline
http://facebook.com/METAV.fanpage
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http://www.youtube.com/metaltradefair
https://de.industryarena.com/metav