Attendees of this month’s International Manufacturing Technology Show were able to see more than 15,000 various manufacturing machine tools, controls, components, software, systems and processes in one location. Here we highlight some notable finds and applied commonalities we uncovered while in attendance.

---

The 26th edition of the International Manufacturing Technology Show (IMTS), September 6-13, included more than 1,200 exhibitors and is estimated to have welcomed some 85,000 visitors from at least 80 countries. The tradeshow showcased more than 15,000 new machine tools, controls, computers, software, components, systems and processes designed to improve efficiency. Vendors displayed equipment in myriad product categories, including metal cutting, tooling and work-holding systems, metal forming and fabricating, controls and computer-aided design (CAD), machine components, and so much more.

As such, it seems somewhat daunting to attempt to pick out and ratify the key trends from the many, diverse manufacturing machines and their uses. Nonetheless, there were some notable standout trends.

Multi-tasking
Multi-tasking, for one, played a key determinant in many of the technologies and their applications. Multi-task machining gets it name because at any given time, multiple machining operations can be occurring in parallel (either on a single spindle or across multiple spindles). Actually, multi-task machine tools represent one of the fastest growing machine tool segments in the market, primarily due to their ability to machine a wide variety of parts entirely within their working space without human intervention, which increases productivity and quality.

Mazak Corp., whose booth almost always seemed to be swarmed by people, highlighted its Nexus QTN 450M, a high-torque, multitasking CNC turning center that features a 40-hp turning spindle with 1,327 foot-pounds of torque as well as a 12-station turret with a 10-hp, 4,000-rpm milling spindle. The integrated spindle/motor unit achieves speeds as fast as 2,000 rpm. According to the company, the machine’s design emphasizes rigidity in a construction that delivers machining capability while efficiently handling high turning and milling forces.

Also leveraging multitasking machining at IMTS was CNC programming software provider Gibbs and Associates. The new GibbsCAM machine simulation option has enhancements to support simulation and validation of a CNC program’s machine tool motion, including 5-axis simultaneous milling machines. The software offers support not only for multi-task machine tools, but also for turning and mill/turn. Machine tool models can be built and set-up like the real machine tool, and then the CNC program is simulated to validate it prior to running the CNC program on the machine tool. Not only does this allow potential programming errors to be visually identified before they become mistakes on the shop floor, but program inefficiencies can also be recognized and addressed.

“The latest class of multi-tasking machine tools represent just the beginning for machine tool complexity and configurability,” said Bill Gibbs, president and founder of Gibbs and Associates. “We fully expect that multi-tasking machine tools will continue to evolve and place even more extreme requirements on programming systems. The foundation that we’ve put in place with GibbsCAM will allow it to keep pace with this evolution.”

Simulation
As global competition in manufacturing is driving manufacturers to improve process efficiency, implementing the latest simulation software is frequently required for seamless implementation of new machines and processes. Simulation enables manufacturers to reduce or completely eliminate testing and manual prove-out of new NC processes. Cutting test parts on production machines is both impractical and outdated. CNC simulation enables programmers to virtually machine the part on the computer before sending the NC program out to the shop floor, and it includes features that can save hours, days, or even weeks of wasted production time on the machine. By reducing overall process time, manufacturers increase productivity and offer their customers faster turnaround.

Like Gibbs and Associates, CG Tech demonstrated its multitasking and simulation abilities and how the company’s Vericut 6.0 can increase the ability of CNC programmers and manufacturing engineers to analyze and optimize the CNC machining process. The software, which runs under Windows and UNIX operating systems, ties complex machining processes together with the ability to simulate multiple set-ups in a single simulation session. According to the company, “fuller simulation of cutting tool shapes commonly used in production processes shows the NC programmer or manufacturing engineer exactly what will happen when using the tool.” The software leverages the simulation results with additional inspection and documentation abilities.

Further, because generating accurate and safe toolpaths for today’s complex machine tools is increasing the need for off-line simulation, specialist CAM company Delcam‘s Partmaker demonstrated its new full-machine simulation module at the show. The module, which provides full machine simulation based on actual machine solid models, aims to allow PartMaker users to perform a more robust machining simulation than is currently offered by the software. There were large-screen presentations of programmed parts being run on accurate models of several different machine tools. The software is designed for CNC mills, lathes, wire EDM, turn-mill centers and Swiss-type lathes.

UGS Corp., a global provider of product lifecycle management (PLM) software and services, highlighted a number of manufacturing solutions, including Machine Tool Support Kits – which support advanced machine tools with post processors, G-code-driven machine tool simulation, templates and examples.

MachineWorks Ltd, a developer of a leading toolkit for CNC simulation and verification, exhibited its latest technology, too, displaying new functionality that includes enhancements designed primarily to increase performance and improve accuracy. “We are experiencing a stronger demand for sophisticated simulation and collision detection due to the greater complexity and affordability of machine tools,” commented David Manley, Managing Director. “We are extending our expertise acquired as market leaders for simulation in the CAM industry to other areas where material removal and clash detection are important.”

Robots
As for perhaps the most colorful tech highlight of the show, robots were EVERYWHERE. They have become a fact of life in many U.S. manufacturing companies’ shops, as they endeavor to remain profitable while confronted with low-cost foreign competition. Engineers five years ago may have had trouble coordinating the efforts of two or three robots, but with today’s sophisticated algorithms, they can manage dozens.

ABB Robotics, for instance, has expanded its IRB line of 6-axis, shelf-mounted robots for machine loading/unloading with a new model aimed at midsize and large presses. Both models have a new controller that allows for on-line or off-line programming.

Fanuc Robotics showed how its R-2000iB 6-axis robot is designed for part transfer, machine loading and other tasks. With payload capacity from 363 to 462 lb. and 8.6-ft. reach, it has the same work envelope, mounting interface, operation and programming as the R-2000iA model, but its new R-J3iC controller has vibration control that allows faster acceleration/deceleration without vibration. The controller also has an integrated vision function that needs no additional processing software.

One novel entry provided an unprecedented 13 axes of motion by combining two 6-axis articulated arms on a common rotating base, providing human-like flexibility of movement. Motoman‘s new DA20 dual-arm model handles a 44.1-lb. payload per arm, operating in a variety of modes: both arms working together to double the payload capacity; the arms performing tasks independently; directly transfering of a part from one arm to the other; or a “jigless” operation, allowing one arm to hold the part while the other performs operations on it.

Motoman also highlighted its IA20 model, a 7-axis, single-arm robot that can straighten out vertically to take up only 1 sq. ft. of floor space, or straighten out horizontally at a height of about 2 ft. above the floor. Designed to maneuver in very tight areas, the snake-like robot can be mounted on the machine, floor, wall, ceiling or incline. It has a 44.9-in. reach and, like the DA20, it has a payload capacity of 44.1 lb.

As if six axes, seven axes and even 13 axes weren’t enough, Motoman also demonstrated its bartending robot for visitors. OK, so this may not be as handy on the shop floor, but it sure was novel.

As aforementioned, these manufacturing technology “trends” at the IMTS were simply those which seemed to be quickening in improvement and growth. To be honest, there was no real revolutionary tech there, but the real standouts were the new and various ways in which the technologies were applied to industrial work.

For a gallery of random, shot-from-the-hip photos from the IMTS 2006 show floor, click here.

Earlier: IMTS from the Floor: Cutting Up and Welding Back

IMTS from the Floor: Disasters and Appetites for Power

IMTS from the Floor: The Latest Industrial Tech in Action