Tried-and-tested extra touches for production processes

EMO Hannover's homepage lists a number of attractions to elicit interest in the fair — practical forums, fascinating lectures, rousing podium discussions and compelling keynote speakers.

Swiss based Starrag (hall 12, stand B60), at this year’s EMO, is presenting real-life industrial applications with some of the extra touches that are well suited to this fascinating trade fair, from established “Industrie 4.0” solutions to highly efficient machines for machining large titanium and aluminium aero structural components.

The theme of the trade fair, "connecting systems for intelligent production", is being used by the organiser, Verein Deutscher Werkzeugmaschinenfabriken e. V. (German Machine Tool Builders' Association), to promote the world-leading EMO 2017 trade fair in Hannover. While others are still talking about “Industrie 4.0”, Swiss-based Starrag is providing digitally networked production to their customers. With a completion date of summer 2019, six ECOSPEED F 2060s are to be installed at Chengdu Aerospace's aircraft factory to create a “smart factory”, one of the most productive and efficient plants in the world for the complete processing of aluminium structural components. This is just one example of several holistic concepts that have been successfully implemented under the umbrella of Starrag's "Integrated Production System" (IPS). This includes cell controller technology that has been developed in house, thanks to which – according to CEO Walter Börsch – "we can implement digitalised manufacturing solutions with maximum process reliability".

Innovative machines with a small footprint

The new machines in Starrag's Heckert product range which are receiving their world premieres in Hannover are no less innovative. A 30 % reduction in footprint and 15 % increase in productivity set the newly developed Heckert X40 and Heckert H50 machining centres apart from the competition.

The modular structure of these horizontal machining centres with a pallet size of 400 – 500 mm enables them to be configured specifically for the application at hand, from light metal machining to heavy-duty cutting – all offering five-axis machining solutions. As well as providing the optimum flexibility demanded by the marketplace, Starrag also has placed particular focus on future-oriented performance parameters for these machines: a 20 % improvement in chip-to-chip time and rapid traverses of up to 80 m/s.

Automation solutions from a single source

Starrag's portfolio includes solutions for all typical automation requirements, from space-saving production cells to centrally controlled production lines. At the EMO, Starrag is presenting a pallet storage system that is integrated into the Heckert H50, resulting in a minimised footprint. This six-pallet solution provides a cost-effective entry into autonomous production.

New for heavy-duty cutting

Starrag is opening a new chapter thanks to the successful Droop+Rein overhead gantry milling machine (FOG) series. The Bielefeld-based product range is presenting the first high-speed machining centre for extremely heavy and large components that combines the benefits of portal and gantry machines. The Droop+Rein FOGS HD (Heavy Duty) offers almost twice the performance and power of a standard FOGS, due to high machine dynamic smoothing increase of 20 – 30 % in speed and economy.

Extreme precision at 2.0 μm/m
Berthiez RVU 2800/250 machining centres are setting new standards in high-precision machining, thanks to a radial and axial run-out of less than 2 μm. These machines can grind, turn, cut and perform inline measurements on large, heavy components of up to 20 t (max. diameter: 2,500 mm, max. height: 1,500 mm) in a single clamping operation. They are of particular use during the complete processing of discs for gas turbines. These machines can also optionally be equipped for robotic tooling, enabling automated operation. These arguments must be convincing: A large international turbine manufacturer has already ordered six machines.

Highly efficient machining of titanium structural components

The Scharmann ECOFORCE Ti 9 and Ti 13 were developed for use in the aviation industry as they can machine titanium structural components of up to 8,000 mm in length (for example modern military aircraft frames or larger frame components). These machines use an ultra-compact A/C machining head with an extremely powerful geared spindle (1,300 Nm at 5,600 rpm in S1 operation) with a high degree of rigidity. The use of a wide range of pallets (1,000 x 4,000 mm up to 2,500 x 8,000 mm) enables highly efficient machining of a variety of components with high cutting rates of 750 cm³/min (45 in3/min), multiple times that of CNC centres, the otherwise standard solution.

"Learning Nuggets" provide individual training

The complete Starrag product offering has one common denominator: They have all been developed according to Starrag's claim, "Engineering precisely what you value". The customer will only receive exactly what they need and what is relevant to them if they receive the correct service. Starrag Customer Service is presenting a range of customer focused services at EMO Hannover. Throughout the machine’s life cycle our customer service team is committed to partner with our customers to achieve the lowest cost of ownership possible; standard service, spindle service, geometric alignment, production support; preventive maintenance and complete support through to retrofitting and rebuild.

The new Starrag Training Centre at the company's headquarters in Rorschacherberg, Switzerland, which, together with the other centres in Chemnitz and Mönchengladbach, provides tried-and-tested standardised training blocks. Starrag develops customised individual training based on these "learning nuggets". An example was a custom-designed training course lasting several weeks for an aviation company in Malaysia which machines large jet engine housings on a Starrag STC 1800/170. The customer saw the value of having a staff who have receiving optimal training, which then provides reliability for the production process.

A Starrag press conference discussing these topics will take place on 17 September from 6 pm at Kastens Hotel Luisenhof, during which CEO Walter Börsch and his management team will present some of these extra touches for real-life production applications to journalists.

Digital, networked, productive: With a completion date of 2019, one of the most productive and efficient Industry 4.0 plants in the world for the complete processing of aluminium structural components will be created at Chengdu Aerospace's aircraft factory. Graphics: Starrag

Even more compact, even more flexible: Two new Heckert machining centres are being presented at the same time at EMO. Image: Starrag

Record breaking: ECOFORCE Ti 9 and Ti 13 can machine titanium structural components of up to 8,000 mm in length with extremely high cutting rates of 750 cm³/min (45in3/min) several times that of CNC centres, the otherwise standard solution. Image: Starrag

HD features: The new Droop+Rein FOGS HD (Heavy Duty) offers almost twice the performance and power of a standard FOGS, due to high machine dynamic smoothing increase of 20 – 30 % in speed and economy. Image: Starrag

Extreme precision: Berthiez RVU 2800/250 machining centres are setting new standards in high-precision machining, thanks to a radial and axial run-out of less than 2.0 μm/m. These multi tasking machines can grind, turn, cut and perform process measurements on large, heavy components of up to 20 t (max. diameter: 2,500 mm, max. height: 1,500 mm) in a single clamping operation.

Starrag company profile
Engineering precisely what you value

The Starrag Group is a global technology leader which manufactures high-precision machine tools for cutting, turning, boring, and grinding of workpieces made from metallic, composite, and ceramic materials. Its customers include leading companies in the aerospace, energy, transportation and industrial segments. Its portfolio of machine tools is complemented by a wide range of technology and services, and enables the customer to make substantial progress in productivity.

The products are marketed under the Starrag brand name and include the following product lines: Berthiez, Bumotec, Dörries, Droop+Rein, Ecospeed, Heckert, Scharmann, SIP, Starrag and TTL. The corporate group is headquartered in Rorschach, Switzerland, and operates manufacturing plants in Switzerland, Germany, France, Great Britain, and India, as well as sales and service companies in several other important customer countries.

Starrag Group AG is listed on the SIX Swiss Exchange (STGN).