(84 of 70) Optimizing and automating machining processes for enhanced machine tool productivity

Skyrocketing energy and raw material prices, long lead times for machine components, and the scarcity of highly skilled workforce increase costs and reduce profits across all industries working with machine tools. In this climate of uncertainty, how can you increase machine productivity while keeping your investments in check?  And what does “machine productivity” actually mean?

How can machine productivity be efficiently increased?

What exactly is “higher machine productivity” depends on the specific machine(s), workpieces, and processes you use. Here are three ways that can help you increase your productivity with the lowest risk and minimum investment. By adopting some, or all these options, you can grow your revenue and reduce operating costs.

Requirement: Maintaining the same levels of machine(s) output with fewer operators.

Solution: Real-time process stability monitoring, anomalies detection and prevention, avoiding a need in continuous operator presence.

Our solution: Adaptive control (OMM /AC) automatically detects developing anomalous cutting conditions before they cause damage to the cutting tools and workpiece. OMM /AC automatically varies feed rate to avoid dangerous loads on the cutting tools. However, if the anomaly persists, it stop the machine until the operator arrives to investigate and manually resolve the anomaly.

Requirement: Reducing tooling costs and increasing machine throughput without time- and resource-consuming investments in the manual optimization of the NC code.

Solution: Dynamic feed rate control based on real-time cutting conditions.

Our solution: Use adaptive control (OMM/AC) to reduce cycle time as much as possible without modifying the NC code or established cutting processes. Alternatively, users can set advanced optimization policies to maintain machine throughput and lower cutting tools costs. Dynamically managing cutting tool lifetime will reduce overall tooling expenses and increase machine throughput as it enables timely tool replacement, yielding fewer scrap parts and reworks.

Requirement: Reliably detecting tool breakage during machining to allow unsupervised and fully automated manufacturing.

Solution: Real-time reliable and sensitive tool breakage detection.

Our solution: Use our real-time tool breakage detection (AMW/TM) to detect small-sized tool breakages reliably. AMW/TM is a fully automated software solution tightly integrated with SINUMERIK controllers and does not require complex or lengthy configurations or expensive workforce training efforts.

What are the advantages of real-time machining optimization?

Whatever your specific challenges to increase machine productivity, Siemens is ready to support you with its comprehensive portfolio.