materials & tools
materials & tools Pooling knowledge for higher productivity By harnessing all the data created during machining, companies make their processes around 10 % more productive. This was the result of a project where MAPAL together with industry partners pooled previously distributed knowledge and made it available as a digital value-added service. Within the framework of the major research project X- Forge (Everything as a Service) funded by the state of Baden- Württemberg, tool manufacturer MAPAL was the consortium leader of the “Productivity-as-a-Service” (ProdaaS) area. MAPAL cooperated with the machine manufacturer F. Zimmermann and the measurement technology specialist Blum to be able to offer customers solutions from a single source. As an further project partner, Fraunhofer IPA had set out to facilitate the underlying business model between the partners and to assess the value added for the customers. An first pilot project came to an end in mid-2024 after a total of three years. Based on this the digital service offering is to be continuously expanded over the coming years. The members of the working consortium already monitor processes with many sensors that deliver the corresponding data. However existing systems offer only a limited view of the entire system of machines, tools and workpieces. While highly complex expert systems are available to the users on the machine, these individual components do not interact with one another. In reality it’s hardly feasible to bring them together. If problems occur it is accordingly difficult to analyze them afterwards or to optimize ongoing processes. Structured knowledge base for process planning CAM process planning with tool selection, path planning and selection of process parameters provides considerable leverage for increasing productivity. While commissioning a component, further adjustment on the machine is most often necessary for an optimal result. Today the planning dimension is largely decoupled from machining. Knowledge gained on the machine does not necessarily make its way to process planning. Insufficient feedback inhibits the learning effect and results in the machine operator having to start from scratch with each new drilling process. A structured knowledge base from practical application is simply missing in CAM process planning. The project partners contribute various information to the “Productivity-as-a-Service” offer for stable and efficient machining processes. The assessment of the wear on the tools is relevant, understanding under what conditions a bore, for example, was made. It also provides information about the current tool life, allowing tool life prognoses. Blum extracts the corresponding data in a dedicated software service and The “Productivity as a Service” project researched the possibilities of linking separate process and production data and developed a service to help manufacturers with future challenges by harnessing self-learning algorithms makes it available. This measurement data is compared with a MAPAL knowledge database in a process analysis to check if the parameters set on the machine follow the manufacturer’s specifications. At the same time, the status assessment of the machines from F. Zimmermann is incorporated, providing information about the condition of the spindle. Finally a higher-level software module links the various sources together and makes information available in a structured manner. In an error state analysis the user can find a cause at a press of a button. Pilot project: tool performance optimizer The pilot project, which took place at Karl Walter Formenbau, involved a Tool Performance Optimizer. With it the user can correct the settings of the process parameters for drilling in the event of deviations to reduce downtime due to breakage or unplanned tool changes. The database also makes it possible to build on structured, methodically collected and evaluated experience from the past during the planning phase for new, previously unknown applications with the help of similarity searches. The Tool Performance Optimizer is to be marketed via two sales channels. In addition to the traditional solution business offered from a single source, it will also be found on large platforms based on Gaia-X. The goal of the next development step is to record any deviations in an assistance system and warn the user immediately during operation with a traffic light system. For the coming years, self-learning services for autonomous parameter optimization and intelligent CAM process planning is in the pipelines. Finally, end-to-end automation from the drawing to the finished component should be possible from 2029. further information: www.mapal.com 10 no. 2, May 2025
New website and optimized online shop materials & tools LMT Tools has revamped its digital presence and now presents itself with a new website and optimized online shop. The concept aligns closely with the company’s motto “to ease machining” and impresses with a fresh design, new features, a user-friendly experience and a holistic customer journey. LMT Tools stands for excellent performance, outstanding quality, strong innovation, and consistent customer orientation. This applies especially to their tool solutions, but it’s also clearly reflected in their new online presence. As part of the relaunch, the digital business card underwent a comprehensive technical and visual update and was further aligned with customer needs. “With our new online presence, we are pursuing a clear mission: to ease machining. We want to make working with our products as easy and efficient as possible”, says Jörn Grindel, head of global product line at LMT Tools. He adds: “Website and shop merge into a central platform where customers can find all the necessary information about the company, our products, improved shop functions and our diverse product portfolio. This creates a consistent presence and enables a seamless customer experience.” User experience in focus The new website concept puts the user experience front and center, combining modern design with high functionality and unique usability. The user interface is carefully designed into to the smallest detail, featuring a clean layout, fresh design, and intuitive navigation. The web shop is fully integrated now and, thanks to a significantly expanded product range, new features, and the extension to the entire European economic area, offer more choice, transparency and service. Customers benefit from faster and more simple ordering processes as well as better visibility of orders, stock availability and tracking. Find tools faster and order with ease The online product portfolio includes all standard products in the fields of milling, threading, drilling and reaming. PWC tools – solutions for plastics, wood and composite materials – as well as matching indexable inserts for IDM tool bodies are also available in the shop. Clear and convenient entry points are provided for all other inquiries related to rolling systems, gear cutting or custom solutions. A standout feature is the new “tool finder”. This applicationoriented tool search guides users to suitable solutions in just four steps (selection of material, product group, tool design and machining process). The ability to download detailed tool data (STEP & DXF files) further simplifies collaboration. The platform is open to everyone, with prices visible to all users. The ordering function is available to all registered users. Bonus: orders placed through the online shop receive a 3 % discount. No minimum order value is required. The new LMT tools website combines a modern design with high functionality and unique usability Continuous optimization and expansion User-friendly design, helpful features, and an integrated ordering function: with its new online presence, LMT Tools is strengthening its digital brand and creating a central platform for company information, e-commerce and digital services. Website and shop will be developed further continuously. Plans include an academy section with training materials and webinars, new features such as a favorites list and product recommendations, as well as an expansion of the online product portfolio. The website is currently available in German, English and French, with more languages to follow. further information: www.lmt-tools.com Precise and productive CBN profile grinding discs Liebherr-Verzahntechnik GmbH One-, two- or three-ribbed CBN profile grinding discs for internal gears – High-quality internal gears for low-noise use in gearboxes – Increased load capacity due to the high residual compressive stresses with CBN grinding – Individual grain sizes for different applications – Shorter grinding times – Roughing and finishing in a single process – Longer tool life – Time-consuming dressing not necessary with CBN tools Liebherr-Verzahntechnik GmbH, tools.info@liebherr.com, www.liebherr.com
